Genie GS-2668 RT, GS-3268 RT Service Manual

GS-2668 RT from GS6805-44771

GS-3268 RT from GS6805-44771

Part No. 112657

Rev C2

July 2011

June 2007

Introduction

ii

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.

Compliance

Machine Classification

Group A/Type 2,3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper opeation, inspection and scheduled maintenance.

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.

Serial Number Information

Genie Industries offers the following Service

Manuals for these models:

Title Part No.

Genie GS-2668 RT and GS-3268 RT

Service Manual, First Edition

(from serial number 101 to GS6805-44770) ......... 52302

Contact Us:

www.genieindustries.com

e-mail: [email protected]

Copyright © 1998 by Genie Industries

112657 Rev C June 2007

Second Edition, Third 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.

GS-2668 RT • GS-3268 RT Part No. 112657

June 2007

Serial Number Legend

Model: GS-1930

Serial number: GS3005A-12345

Model year: 2005 Manufacture date:

Electrical schematic number: ES0141

Machine unladen weight:

04/12/05

2,714 lb / 1,231 kg

Rated work load (including occupants): 500 lb / 227 kg

Maximum allowable inclination of the chassis:

N/A

Gradeability: N/A

Maximum allowable side force : 100 lb / 445 N

Maximum number of platform occupants: 2

Country of manufacture: USA

This machine complies with:

ANSI A92.6-1999

B354.2-01

Genie Industries

18340 NE 76th Street

Redmond, WA 98052

USA

PN - 77055

INTRODUCTION

GS30 05 A - 12345

Model

Model year

Sequence number

Facility code

( used only for model manufactured in multiple facilities )

Serial number

(stamped on chassis)

Part No. 112657

Serial label

(inside cover)

GS-2668 RT • GS-3268 RT iii

June 2007

This page intentionally left blank.

iv GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 1 • Safety Rules

Safety Rules

Danger

Failure to obey the instructions and safety rules in this manual and the appropriate Operator's

Manual on your machine will result in death or serious injury.

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. 112657 GS-2668 RT • GS-3268 RT v

Section 1 • Safety Rules June 2007

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.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

Be sure to wear protective eye wear and other protective clothing if the situation warrants it.

unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

Be aware of potential crushing hazards such as moving parts, free swinging or

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 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.

Be sure that your workshop or work area is properly ventilated and well lit.

vi GS-2668 RT • GS-3268 RT Part No. 112657

November 2008

Table of Contents

Introduction

Section 1

Section 2

Section 3

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

ii

Serial Number Information ..................................................................................

ii

Serial Number Legend .......................................................................................

iii

Safety Rules

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

v

Rev Specifications

D Machine Specifications ................................................................................ 2 - 1

Performance Specifications ......................................................................... 2 - 2

Hydraulic Components Specifications .......................................................... 2 - 3

Manifold Component Specifications ............................................................. 2 - 4

Valve Coil Resistance Specifications ........................................................... 2 - 4

Kubota D1105 Engine Tier 4 ......................................................................... 2 - 5

Kubota D905 Engine Tier 2 ........................................................................... 2 - 6

Kubota DF752 Engine .................................................................................. 2 - 7

Perkins 403D-11 Engine ............................................................................... 2 - 8

Perkins 403C-11 Engine ............................................................................... 2 - 9

Hydraulic Hose and Fitting Torque Specifications ....................................... 2 - 10

SAE and Metric Fasteners Torque Charts .................................................. 2 - 11

Rev Scheduled Maintenance Procedures

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

Pre-delivery Preparation Report .................................................................... 3 - 3

Maintenance Inspection Report .................................................................... 3 - 5

Part No. 112657 GS-2668 RT • GS-3268 RT vii

November 2008

TABLE OF CONTENTS

Section 3 Rev Scheduled Maintenance Procedures , continued

B Checklist A Procedures

A-1 Inspect the Manuals and Decals ......................................................... 3 - 7

A-2 Perform Pre-operation Inspection ........................................................ 3 - 8

A-3 Perform Function Tests ...................................................................... 3 - 8

A-4 Perform Engine Maintenance .............................................................. 3 - 9

A-5 Inspect the Engine Air Filter ................................................................ 3 - 9

A-6 Perform 30 Day Service .................................................................... 3 - 10

B

A-7 Perform Engine Maintenance - Kubota Models .................................. 3 - 11

A-8 Perform Engine Maintenance - Kubota Models .................................. 3 - 11

A-9 Perform Engine Maintenance - Kubota Models .................................. 3 - 12

A-10 Perform Engine Maintenance - Kubota Models .................................. 3 - 12

A-11 Drain the Fuel Filter/Water Separator - Diesel Models ....................... 3 - 13

A-12 Perform Engine Maintenance - Kubota Models .................................. 3 - 14

Checklist B Procedures

B-1 Inspect the Battery ........................................................................... 3 - 15

B-2 Inspect the Electrical Wiring ............................................................. 3 - 16

B-3 Inspect the Tires, Wheels and Lug Bolt Torque ................................. 3 - 17

B-4 Perform Engine Maintenance - Perkins Models ................................. 3 - 17

B-5 Test the Key Switch ......................................................................... 3 - 18

B-6 Test the Emergency Stop ................................................................. 3 - 18

B-7 Test the Automotive-style Horn ......................................................... 3 - 19

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 viii GS-2668 RT • GS-3268 RT Part No. 112657

November 2008

Section 3

TABLE OF CONTENTS

Rev Scheduled Maintenance Procedures , continued

B-11 Test the Drive Speed - Raised Position ............................................. 3 - 22

B

B-12 Inspect the Fuel and Hydraulic Tank Cap Venting Systems .............. 3 - 22

B-13 Perform Hydraulic Oil Analysis ......................................................... 3 - 23

B-14 Test the Flashing Beacons (if equipped) ........................................... 3 - 24

B-15 Perform Engine Maintenance - Kubota Models .................................. 3 - 24

Checklist C Procedures

C-1 Test the Platform Overload System (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

B

C-4 Perform Engine Maintenance - Diesel Models .................................. 3 - 27

C-5 Perform Engine Maintenance - Kubota Models ................................ 3 - 28

Checklist D Procedures

D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 29

D-2 Replace the Hydraulic Tank Return Filter ......................................... 3 - 30

D-3 Perform Engine Maintenance - Perkins Models ................................ 3 - 31

D-4 Perform Engine Maintenance - Kubota Models ................................ 3 - 31

D-5 Perform Engine Maintenance - Kubota Models ................................ 3 - 32

B Checklist E Procedures

E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 33

E-2 Perform Engine Maintenance - Perkins Models ................................ 3 - 34

E-3 Perform Engine Maintenance - Gasoline/LPG Models ...................... 3 - 35

E-4 Perform Engine Maintenance - Kubota D1105 Models ..................... 3 - 35

E-5 Perform Engine Maintenance - Perkins Models ................................ 3 - 36

E-6 Perform Engine Maintenance - Kubota D1105 Models ..................... 3 - 36

Part No. 112657 GS-2668 RT • GS-3268 RT ix

November 2008

TABLE OF CONTENTS

Section 4 Rev Repair Procedures

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

A Platform Controls

1-1 Circuit Boards .................................................................................... 4 - 2

A

B

Platform Components

2-1 Platform ............................................................................................. 4 - 3

2-2 Platform Extension ............................................................................. 4 - 4

Scissor Components

C

3-1 Scissor Assembly, GS-2668 RT ......................................................... 4 - 6

3-2 Scissor Assembly, GS-3268 RT ....................................................... 4 - 12

3-3 Wear Pads ....................................................................................... 4 - 19

3-4 Lift Cylinder(s) .................................................................................. 4 - 20

Kubota D1105 and D905 Engines

4-1 Timing Adjustment ........................................................................... 4 - 23

4-2 Glow Plugs ...................................................................................... 4 - 23

4-3 Engine RPM ..................................................................................... 4 - 24

A

4-4 Flex Plate ......................................................................................... 4 - 24

4-5 Coolant Temperature and Oil Pressure Switches ............................. 4 - 25

Kubota DF752 Engine

5-1 Timing Adjustment ........................................................................... 4 - 27

5-2 Carburetor Adjustment - Gasoline/LPG Models ............................... 4 - 27

5-3 Choke Adjustment - Gasoline/LPG Models ...................................... 4 - 27

5-4 Flex Plate ......................................................................................... 4 - 27

5-5 Coolant Temperature and Oil Pressure Switches ............................. 4 - 27

5-6 Engine RPM ..................................................................................... 4 - 28 x GS-2668 RT • GS-3268 RT Part No. 112657

November 2008

Section 4

TABLE OF CONTENTS

Rev Repair Procedures, continued

B Perkins 403D-11 and 403C-11 Engines

6-1 Engine RPM ..................................................................................... 4 - 29

6-2 Timing Adjustment ............................................................................ 4 - 29

B

6-3 Flex Plate ......................................................................................... 4 - 30

6-4 Coolant Temperature and Oil Pressure Switches .............................. 4 - 30

Ground Controls

7-1 Auxiliary Platform Lowering .............................................................. 4 - 32

A

B

7-2 Function Speed Tuning ..................................................................... 4 - 32

7-3 Software Configuration ...................................................................... 4 - 37

7-4 Level Sensor - Models without Outriggers ......................................... 4 - 43

7-5 Level Sensor - Models with Outriggers .............................................. 4 - 46

Hydraulic Pump

8-1 Function Pump ................................................................................. 4 - 50

Manifolds

9-1 Function Manifold Components ........................................................ 4 - 52

9-2 Valve Adjustments - Function Manifold ............................................ 4 - 56

9-3 Outrigger Manifold Components ........................................................ 4 - 59

9-4 Valve Adjustments - Outrigger Manifold ............................................ 4 - 60

9-5 Generator Manifold Components ....................................................... 4 - 62

9-6 Valve Adjustments - Generator Manifold ........................................... 4 - 63

9-7 Valve Coils ....................................................................................... 4 - 64

Part No. 112657 GS-2668 RT • GS-3268 RT xi

November 2008

TABLE OF CONTENTS

Section 4

Section 5

Rev Repair Procedures, continued

A Fuel and Hydraulic Tanks

10-1 Fuel Tank ......................................................................................... 4 - 66

10-2 Hydraulic Tank ................................................................................. 4 - 67

A Steer Axle Components

11-1 Yoke and Drive Motor ....................................................................... 4 - 68

11-2 Steer Cylinder ................................................................................... 4 - 70

11-3 Tie Rod ............................................................................................. 4 - 70

A

A

A

A

Non-steer Axle Components

12-1 Drive Motor and Brake ...................................................................... 4 - 71

Outrigger Components

13-1 Outrigger Cylinder ............................................................................. 4 - 72

Brake Release Hand Pump Components

14-1 Brake Release Hand Pump Components .......................................... 4 - 73

Platform Overload Components

15-1 Platform Overload System ............................................................... 4 - 74

Rev Fault Codes

Introduction .................................................................................................. 5 - 1

B Fault Code Chart (from serial number GS6805-44771) .................................. 5 - 3 xii GS-2668 RT • GS-3268 RT Part No. 112657

November 2008

Section 6

TABLE OF CONTENTS

B

A

C

Rev Schematics

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

A

A

Electronic Control Module Layout

(from serial number GS6805-44771) ........................................................... 6 - 2

Electronic Control Module Pin-Out Legend

(from serial number GS6805-44771) ........................................................... 6 - 3

A Wiring Diagram - Platform Control Box

(from serial number GS6805-44771) ........................................................... 6 - 4

Electrical Schematics Abbreviation and Wire Color Legends ....................... 6 - 6

Electrical Symbols Legend ........................................................................... 6 - 7

C

C

C

Electrical Schematic - ANSI Models with Gasoline/LPG Power

(from serial number GS6805-44771) ........................................................... 6 - 8

Electrical Schematic - CE Models with Gasoline/LPG Power

(from serial number GS6805-44771) ......................................................... 6 - 12

Electrical Schematic - ANSI Models with Diesel Power

(from serial number GS6805-44771 to GS6806-45204) ............................ 6 - 16

Electrical Schematic - ANSI Models with Diesel Power

(from serial number GS6806-45205) ......................................................... 6 - 20

C

C

A

C

Electrical Schematic - CE Models with Diesel Power

(from serial number GS6805-44771 to GS6806-45204) ............................ 6 - 24

Electrical Schematic - CE Models with Diesel Power

(from serial number GS6806-45205) ......................................................... 6 - 28

Hydraulic Symbols Legend ........................................................................ 6 - 31

Hydraulic Schematic

(from serial number GS6805-44771) ......................................................... 6 - 32

Part No. 112657 GS-2668 RT • GS-3268 RT xiii

June 2007

This page intentionally left blank.

xiv GS-2668 RT • GS-3268 RT Part No. 112657

July 2011 Section 2 • Specifications

Specifications

REV D

Machine Specifications

Fluid capacities

Hydraulic tank

Hydraulic system with outriggers

(including tank), GS-2668 RT

Hydraulic system with outriggers

(including tank), GS-3268 RT

Hydraulic system without outriggers

(including tank), GS-2668 RT

Hydraulic system without outriggers

(including tank), GS-3268 RT

Fuel tank

15 gallons

56.8 liters

15.75 gallons

59.6 liters

16.5 gallons

62.5 liters

15.5 gallons

58.7 liters

16.25 gallons

61.5 liters

14.5 gallons

54.9 liters

Tire and wheels

Wheel lugs

Lug bolt torque, dry

Lug bolt torque, lubricated

Castle nut torque, dry

Castle nut torque, lubricated

Rough Terrain, foam-filled

Tire size

Tire ply rating

Tire diameter

For operational specifications, refer to the

Operator's Manual.

Tire width

Tire weight, new foam-filled (minimum)

Non-marking, solid rubber

Tire size

Tire diameter

Tire width

Weight

6 @ 1 / 2 -20

90 ft-lbs

122 Nm

67.5 ft-lbs

91.5 Nm

300 ft-lbs

406.7 Nm

225 ft-lbs

305 Nm

26 x 12D380

8

26 in

66 cm

12 in

30 cm

170 lbs

77 kg

22 x 16 x 9 in

55.9 x 40.6 x 22.9 cm

22 in

55.9 cm

9 in

22.9 cm

120 lbs ( + / 1 lbs)

54.4 kg ( + / 2.2 kg)

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice.

Part No. 112657 GS-2668 RT • GS-3268 RT 2 - 1

Section 2 • Specifications July 2011

SPECIFICATIONS REV D

Performance Specifications

Drive speed, maximum

Platform stowed

Platform raised

3.8 mph

6.1 km/h

40 ft / 7.2 sec

12.2 m / 7.2 sec

0.5 mph

0.8 km/h

40 ft / 54.6 sec

12.2 m / 54.6 sec

Braking distance, maximum

High range on paved surface less than 5 ft less than 1.5 m

Gradeability

GS-2668 RT

GS-3268 RT

40%

35%

Function speed, maximum from platform controls

(with maximum rated load in platform)

GS-2668 RT

Platform up

Platform down

GS-3268 RT

Platform up

Platform down

Outrigger leveling, maximum

Front to back

Side to side

28 to 32 seconds

33 to 37 seconds

38 to 42 seconds

35 to 39 seconds

5.5°

10°

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice.

Hydraulic Specifications

Hydraulic Oil Specifications

Hydraulic oil type

Viscosity grade

Viscosity index

Chevron Rykon MV equivalent

Multi-viscosity

200

Cleanliness level, minimum

Water content, maximum

15/13

200 ppm

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 the viscosity index should exceed 140. They should provide excellent antiwear, oxidation, corrosion inhibition, seal conditioning, and foam and aeration suppression properties.

Optional fluids

Biodegradable

Fire resistant

Petro Canada Environ MV 46

Statoil Hydra Way Bio Pa 32

BP Biohyd SE-S

UCON Hydrolube HP-5046

Quintolubric 822

Mineral based Shell Tellus T32

Shell Tellus T46

Chevron Aviation A

Continued use of Chevron

Aviation A hydraulic fluid when ambient temperatures are consistently above 32°F / 0°C may result in component damage.

Note: Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below

0°F / -17°C.

Note: Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205°F / 96°C.

Note: 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. 112657

July 2011 Section 2 • Specifications

REV D SPECIFICATIONS

Hydraulic Components

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)

Displacement per revolution (pump #2)

Flow rate @ 3600 rpm

(pump #2)

Hydraulic tank return filter

Function manifold

System relief valve pressure

(pump #1)

System relief valve pressure

(pump #2)

Lift relief valve pressure, GS-2668 RT

6.5 gpm

24.6 L/min

0.488 cu in

8 cc

6.5 gpm

24.6 L/min

10 micron with

25 psi / 1.7 bar bypass

3500 psi

241.3 bar

3000 psi

207 bar

3600 psi

248.2 bar

Lift relief valve pressure, GS-3268 RT

Steer relief valve pressure

Steer flow regulator

2800 psi

193 bar

2800 psi

193 bar

2 gpm

7.5 L/min

Outrigger manifold

Relief valve pressure

Generator manifold

Relief valve pressure

Flow rate

Drive motors

Displacement

2000 psi

137.8 bar

3000 psi

206.8 bar

4.5 gpm

17 L/min

28.3 cu in

464 cc

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice.

Part No. 112657 GS-2668 RT • GS-3268 RT 2 - 3

Section 2 • Specifications July 2011

SPECIFICATIONS REV D

Manifold Component

Specifications

Plug torque

SAE No. 4

SAE No. 6

SAE No. 8

SAE No. 10

13 ft-lbs / 18 Nm

18 ft-lbs / 24 Nm

50 ft-lbs / 68 Nm

55 ft-lbs / 75 Nm

Valve Coil Resistance

Specifications

Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / 20°C that your air temperature increases or decreases from 68°F / 20°C.

Description

Solenoid valve, 2 position 2 way

12V DC with diode (schematic item AI)

Specification

9 Ω

Solenoid valve, 2 position 2 way

12V DC (schematic item BB)

Solenoid valve, 2 position 3 way

12V DC with diode (schematic item FP)

7.5

Ω

Solenoid valve, 3 position 4 way

12V DC (schematic item BD)

7.5

Ω

Solenoid valve, 2 position 2 way

10V DC (schematic items CA, CB, CC and CD)

Solenoid valve, 3 position 4 way

12V DC with diode (schematic item FF)

8.2

Ω

Solenoid valve, 2 position 3 way

12V DC (schematic item DA)

Solenoid valve, 3 position 4 way

12V DC with diode (schematic items FE and FR)

6 Ω

Solenoid valve, 2 position 2 way

12V DC with diode (schematic items FB and FK)

8.8

Ω

Solenoid valve, 2 position 4 way

12V DC with diode (schematic items FD, FQ and FT)

5

Ω

5 Ω

8.8

Ω

8.8

Ω

Proportional valve,

12V DC (schematic item FU)

5 Ω

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice.

2 - 4 GS-2668 RT • GS-3268 RT Part No. 112657

July 2011 Section 2 • Specifications

REV D SPECIFICATIONS

Kubota D1105 Engine Tier 4

Displacement 68.53 cu in

1.123 liters

Number of cylinders

Bore and stroke

Horsepower,

Firing order gross intermittent

Compression ratio

Compression pressure

3

3.07 x 3.09 inches

78 x 78.4 mm

24.8 @ 3000 rpm

18.5 kW

1 - 2 - 3

24:1

412 to 469 psi

28.4 to 32.3 bar

Low idle

Frequency

High idle

Frequency

Governor

Valve clearance, cold

Engine coolant capacity

1500 rpm

300 hz

3000 rpm

600 hz 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)

28 to 64 psi

1.93 to 4.41 bar

5.4 quarts

5.1 liters

Oil viscosity requirements

Units ship with 15W-40.

Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the

Engine Operator Handbook on your machine.

Injection system

Injection pump make

Injection timing

Injection pump pressure

Bosch MD

16.25° to 17.75° BTDC

1992 to 2133 psi

137 to 147 bar

Fuel requirement

For fuel requirements, refer to the engine Operator's

Manual on your machine.

Battery

Type

Group

Quantity

Ampere hour

Cold cranking ampere

Reserve capacity @ 25A rate

Alternator

Output

Fan belt deflection

12V DC

34/78

1

75 A

900A

125 minutes

40A, 14V DC

0.28 to 0.35 inch

7 to 9 mm

Continuous improvement of our products is a

Genie policy. Product specifications are subject to change without notice.

Part No. 112657 GS-2668 RT • GS-3268 RT 2 - 5

Section 2 • Specifications July 2011

SPECIFICATIONS REV D

Kubota D905 Engine Tier 2

Displacement 54.86 cu in

0.898 liters

Number of cylinders

Bore and stroke

Horsepower,

Firing order

Gross intermittent

Compression ratio

Compression pressure

3

2.83 x 2.90 inches

72 x 73.6 mm

23.5 @ 3600 rpm

17.5 kW

1 - 2 - 3

23:1

412 to 469 psi

28.4 to 32.3 bar

Low idle

Frequency

High idle

Frequency

Governor

Valve clearance, cold

Engine coolant capacity

1500 rpm

300 hz

3000 rpm

600 hz 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)

36 to 64 psi

2.48 to 4.41 bar

5.4 quarts

5.1 liters

Oil viscosity requirements

Units ship with 15W-40.

Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the

Engine Operator Handbook on your machine.

Injection system

Injection pump make

Injection timing

Injection pump pressure

Bosch MD

18° to 21° BTDC

1991 psi

137 bar

Fuel requirement

For fuel requirements, refer to the engine Operator's

Manual on your machine.

Battery

Type

Group

Quantity

Ampere hour

Cold cranking ampere

Reserve capacity @ 25A rate

Alternator

Output

Fan belt deflection

12V DC

34/78

1

75 A

900A

125 minutes

30A, 14V DC

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. 112657

July 2011 Section 2 • Specifications

REV D SPECIFICATIONS

Kubota DF752 Engine

Displacement

Number of cylinders

Bore & stroke

Horsepower, Gross intermittent

45.21 cu in

0.74 liters

3

2.68 x 2.68 inches

68 x 68 mm

24.8 @ 3600 rpm

18.5 kW @ 3600 rpm

Firing order

Compression ratio

Compression pressure

1 - 2 - 3

9.2:1

128 to 185 psi

8.8 to 12.7 bar

Low idle

Frequency

High idle

Frequency

Governor

Valve clearances, cold

Engine coolant capacity

1500 rpm

300 hz

3200 rpm

640 hz

centrifugal ball mechanical

Lubrication system

Oil pressure

(operating temperature @ 3850 rpm)

Oil capacity (including filter)

0.0057 to 0.0072 inches

0.145 to 0.185 mm

3.1 quarts

2.9 liters

28 to 64 psi

1.9 to 4.4 bar

3.4 quarts

3.25 liters

Oil viscosity requirements

Units ship with 15W-40.

Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the

Engine Operator Handbook on your machine.

Fuel pump

Fuel pressure, static

Fuel flow rate

2.84 psi

0.19 bar

0.125 gpm

0.47 L/min

Starter motor

Brush length, new

Brush length wear limit

Brush spring tension

0.669 in

17 mm

0.453 in

11.5 mm

50 to 91 ounces

13.7 to 25.5 N

Battery

Type 12V DC

34/78 Group

Quantity 1

75AH Ampere hour

Cold cranking ampere

#3 Spark plug wire resistance

Spark plug type

Spark plug gap

900A

125 minutes Reserve capacity at 25A rate

Ignition System

Ignition spark advance

Ignition coil primary resistance

Ignition coil secondary resistance

#1 Spark plug wire resistance

#2 Spark plug wire resistance

18° BTDC

1.3 to 1.6

Ω

@ 75°F / 24°C

10.7 to 14.5 k Ω

@ 75°F / 24°C

2.81 to 4.79k

Ω

3.4 to 5.8k

Ω

3.57 to 6.09k

Ω

NGK BKR4E-11

0.039 to 0.043 inches

1 to 1.1 mm

Alternator

Output

Fan belt deflection

30A, 14V DC

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 2 - 7

Section 2 • Specifications July 2011

SPECIFICATIONS REV D

Perkins 403D-11 Engine

Displacement

Number of cylinders

Bore and stroke

Horsepower, gross intermittent

68.9 cu in

1.13 liters

3

3.03 x 3.19 inches

77 x 81 mm

28.2 @ 3400 rpm

21 kW

Firing order

Compression ratio

Compression pressure

1 - 2 - 3

23:1

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

Low idle

Frequency

High idle

Frequency

1500 rpm

300 hz

3000 rpm

600 hz all-speed mechanical Governor

Valve clearance, cold 0.0078 in

0.2 mm

Engine coolant capacity

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

3.28 quarts

3.1 liters

Oil pressure

(hot @ 2000 rpm)

Oil capacity (including filter)

40 to 60 psi

2.76 to 4.14 bar

4.6 quarts

4.4 liters

Oil viscosity requirements

Units ship with 15W-40.

Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the

Engine Operator Handbook on your machine.

Injection system

Injection pump make

Injection timing

Injection pump pressure

Fuel requirement

Battery

Type

Group

Quantity

Ampere hour

Cold cranking ampere

Reserve capacity @ 25A rate

Alternator

Output

Fan belt deflection

Bosch

23° BTDC @ 3000 rpm

2133 psi

150 bar diesel number 2-D

12V DC

34/78

1

75AH

900A

125 minutes

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.

2 - 8 GS-2668 RT • GS-3268 RT Part No. 112657

July 2011 Section 2 • Specifications

REV D SPECIFICATIONS

Perkins 403C-11 Engine

Displacement

Number of cylinders

Bore and stroke

Horsepower, gross intermittent

68.9 cu in

1.13 liters

3

3.03 x 3.19 inches

77 x 81 mm

26.1 @ 3000 rpm

19.5 kW

Firing order

Compression ratio

Compression pressure

1 - 2 - 3

23:1

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

Low idle

Frequency

High idle

Frequency

1500 rpm

300 hz

3000 rpm

600 hz all-speed mechanical Governor

Valve clearance, cold 0.0078 in

0.2 mm

Engine coolant capacity

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

3.28 quarts

3.1 liters

Oil pressure

(hot @ 2000 rpm)

Oil capacity (including filter)

40 to 60 psi

2.76 to 4.14 bar

4.3 quarts

4.07 liters

Oil viscosity requirements

Units ship with 15W-40.

Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the

Engine Operator Handbook on your machine.

Injection system

Injection pump make

Injection timing

Injection pump pressure

Fuel requirement

Battery

Type

Group

Quantity

Ampere hour

Cold cranking ampere

Reserve capacity @ 25A rate

Alternator

Output

Fan belt deflection

Bosch

23° BTDC @ 3000 rpm

2133 psi

150 bar diesel number 2-D

12V DC

34/78

1

75AH

900A

125 minutes

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 2 - 9

Section 2 • Specifications July 2011

SPECIFICATIONS REV D

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.

SAE O-ring Boss Port

(tube fitting - installed into Aluminum)

SAE Dash size

-4

-6

-8

-10

-12

-16

-20

-24

Torque

11 ft-lbs / 14.9 Nm

23 ft-lbs / 31.2 Nm

40 ft-lbs / 54.2 Nm

69 ft-lbs / 93.6 Nm

93 ft-lbs / 126.1 Nm

139 ft-lbs / 188.5 Nm

172 ft-lbs / 233.2 Nm

208 ft-lbs / 282 Nm

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.

Note: 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).

2 Lubricate the O-ring before installation.

3 Be sure that the face seal O-ring is seated and retained properly.

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

(tube fitting - installed into Steel)

SAE Dash size

-4

-6

-8

-10

-12

-16

-20

-24

Torque

16 ft-lbs / 21.7 Nm

35 ft-lbs / 47.5 Nm

60 ft-lbs / 81.3 Nm

105 ft-lbs / 142.4 Nm

140 ft-lbs / 190 Nm

210 ft-lbs / 284.7 Nm

260 ft-lbs / 352.5 Nm

315 ft-lbs / 427.1 Nm

Seal-Lok

®

Fittings

(hose end)

SAE Dash size

-4

-6

-8

-10

-12

-16

-20

-24

Torque

18 ft-lbs / 24.4 Nm

27 ft-lbs / 36.6 Nm

40 ft-lbs / 54.2 Nm

63 ft-lbs / 85.4 Nm

90 ft-lbs / 122 Nm

120 ft-lbs / 162.7 Nm

140 ft-lbs / 190 Nm

165 ft-lbs / 223.7 Nm

2 - 10 GS-2668 RT • GS-3268 RT Part No. 112657

July 2011 Section 2 • Specifications

REV D SPECIFICATIONS

1/4

20

28

SAE FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

SIZE THREAD Grade 5

LUBED in- lbs

80

90

N m

9

10.1

in- lbs

100

120

DRY

N m

11.3

13.5

Grade 8

LUBED in- lbs

110

120

N m

12.4

13.5

in- lbs

140

160

DRY

N m

15.8

18

A574 High Strength

Black Oxide Bolts

LUBED in- lbs

130

140

N m

14.7

15.8

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

1

1

/

8

1

1

/

4

1

1

/

2

18

10

16

9

14

13

20

12

18

11

18

24

16

24

14

20

8

12

7

12

7

12

6

12

LUBED f t - lbs

220

320

350

480

530

590

670

840

930

1460

1640

64

80

90

110

130

200

13

14

23

26

37

41

57

N m

298

433

474

650

718

800

908

1138

1260

1979

2223

17.6

19

31.2

35.2

50.1

55.5

77.3

86.7

108.4

122

149

176

271

DRY

N m

406

583

637

867

962

1071

1206

1518

1681

2643

2969

115

149

162

203

230

366

23

25.7

42

47.4

66.4

74.5

101.6

f t - lbs

300

430

470

640

710

790

890

1120

1240

1950

2190

85

110

120

150

170

270

17

19

31

35

49

55

75

LUBED f t - lbs

310

450

500

680

750

970

1080

1360

1510

2370

2670

90

120

130

160

180

280

18

20

33

37

50

60

80

N m

420

610

678

922

1016

1315

1464

1844

2047

3213

3620

122

162

176

217

244

379

24

27.1

44.7

50.1

67.8

81.3

108.4

DRY

N m

569

827

908

1233

1342

1749

1952

2467

2725

4284

4826

162

203

230

284

325

515

33.9

36.6

59.6

66.4

94.7

108.4

149 f t - lbs

420

610

670

910

990

1290

1440

1820

2010

3160

3560

120

150

170

210

240

380

25

27

44

49

70

80

110 f t - lbs

350

510

560

770

840

1090

1220

1530

1700

2670

3000

105

130

140

180

200

320

21

24

38

43

61

68

93

LUBED

N m

474

691

759

1044

1139

1477

1654

2074

2304

3620

4067

142

176

189

244

271

433

28.4

32.5

51.5

58.3

82.7

92.1

126

METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

Size Class 4.6

4.6

Class 8.8

8.8

Class 10.9

10.9

Class 12.9

12.9

(m m )

5

6

7

LUBED DRY LUBED DRY LUBED DRY LUBED DRY in- lbs

16

N m in- lbs

1.8

19 3.05

45 5.12

21

36

N m in- lbs

2.4

4.07

41

69

N m in- lbs

4.63

54

7.87

93

N m in- lbs

6.18

58

N m in- lbs

6.63

78

10.5

100 11.3

132

N m in- lbs

8.84

15

68

N m in- lbs

7.75

91

N m

10.3

116 13.2

155 17.6

60 6.83

116 13.2

155 17.6

167 18.9

223 25.2

1.95

22.1

260 29.4

LUBED DRY LUBED DRY LUBED DRY LUBED DRY f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m

8 5.4

7.41

7.2

9.88

14 19.1

18.8

25.5

20.1

27.3

26.9

36.5

23.6

32 31.4

42.6

10 10.8

14.7

14.4

19.6

27.9

37.8

37.2

50.5

39.9

54.1

53.2

72.2

46.7

63.3

62.3

84.4

12 18.9

25.6

25.1

34.1

48.6

66 64.9

88 69.7

94.5

92.2

125 81 110 108 147

14 30.1

40.8

40 54.3

77.4

105 103 140 110 150 147 200 129 175 172 234

16 46.9

63.6

62.5

84.8

125 170 166 226 173 235 230 313 202 274 269 365

18 64.5

87.5

86.2

117 171 233 229 311 238 323 317 430 278 377 371 503

20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713

22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970

24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

Part No. 112657 GS-2668 RT • GS-3268 RT 2 - 11

Section 2 • Specifications November 200

This page intentionally left blank.

2 - 12 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:

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.

Failure to perform each procedure as presented and scheduled could result in death, serious injury or substantial damage.

Immediately tag and remove from service a damaged or malfunctioning machine.

Repair any machine damage or malfunction before operating the machine.

Use only Genie approved replacement parts.

Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.

Unless otherwise specified, perform each maintenance 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

· Wheels chocked

· All external AC power supply disconnected from the machine

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.

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.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 1

Section 3 • Scheduled Maintenance Procedures November 2008

SCHEDULED MAINTENANCE PROCEDURES

Maintenance Symbols Legend

Note: 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.

Indicates that a warm engine will be required to perform this procedure.

Indicates that dealer service will be required to perform this procedure.

Pre-delivery Preparation Report

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

Semi-annually or every 500 hours

Annually or every 1000 hours

Two year or every 2000 hours

Checklist

A

A + B

A + B + C

A + B + C + D

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. Maintain completed forms for a minimum of 4 years or in compliance with your employer, jobsite and governmental regulations and requirements.

3 - 2 GS-2668 RT • GS-3268 RT Part No. 112657

Pre-Deliver y Preparation

November 2008

Fundamentals

It is the responsibility of the dealer to perform the

Pre-delivery Preparation.

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.

Section 3 • Scheduled Maintenance Procedures

Instructions

Use the operator’s manual on your machine.

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

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Y N R

Genie Industries USA

18340 NE 76th Street

PO Box 97030

Redmond, WA 98073-9730

(425) 881-1800

Part No. 112657

Industries. Rev B

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Genie UK

The Maltings, Wharf Road

Grantham, Lincolnshire

NG31- 6BH England

(44) 1476-584333

GS-2668 RT • GS-3268 RT 3 - 3

Section 3 • Scheduled Maintenance Procedures November 2008

This page intentionally left blank.

3 - 4 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

Maintenance Inspection Report

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

· Make copies of this report to use for each inspection.

· Select the appropriate checklist(s) for the type of inspection to be performed.

Daily or 8 hours

Inspection:

Quarterly or 250 hours

Inspection:

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

· 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

Checklist A - Rev B

A-1 Manuals and decals

A-2 Pre-operation inspect

A-3 Function tests

A-4 Engine maintenance

Perform every 40 hours:

A-5 Engine air filter

Perform after 40 hours:

A-6 Perform 30 day service

Perform after 50 hours:

A-7 Engine maintenance -

Kubota models

Perform every 50 hours:

A-8 Engine maintenance -

Kubota models

Perform every 100 hours:

A-9 Engine maintenance -

Kubota models

Perform every 200 hours:

A-10 Engine maintenance -

Kubota models

A-11 Drain filter/separator -

Diesel models

Perform every 1-2 months:

A-12 Engine maintenance -

Kubota models

Y N R

Comments

Checklist B - Rev B

B-1 Battery

B-2 Electrical wiring

B-3 Tires and wheels

B-4 Engine maintenance -

Perkins models

B-5 Key switch

B-6 Emergency Stop

B-7 Horn

B-8 Fuel select -

Gasoline/LPG models

B-9 Drive brakes

B-10 Drive speed - stowed

B-11 Drive speed - raised

B-12 Tank venting systems

B-13 Hydraulic oil analysis

B-14 Flashing beacons

(if equipped)

Perform every 400 hours:

B-15 Engine maintenance -

Kubota models

Y N R

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 5

Section 3 • Scheduled Maintenance Procedures November 2008

MAINTENANCE INSPECTION REPORT

Model

Serial number

Date

Hour meter

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

Instructions

· Make copies of this report to use for each inspection.

· Select the appropriate checklist(s) for the type of inspection to be performed.

Daily or 8 hours

Inspection: A

Quarterly or 250 hours

Inspection: 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

· 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

Checklist C - Rev B

C-1 Platform overload

(if equipped)

C-2 Fuel tank -

Diesel models

C-3 Breather cap - models with optional oil

C-4 Engine maintenance -

Diesel models

Perform every 800 hours:

C-5 Engine maintenance -

Kubota models

Y N R

Checklist D - Rev B

D-1 Scissor arm wear pads

D-2 Hydraulic filter

D-3 Engine maintenance -

Perkins models

D-4 Engine maintenance -

Kubota models

Perform every 1500 hours:

D-5 Engine maintenance -

Kubota models

Y N R

Comments

Checklist E - Rev B

E-1 Test or replace hydraulic oil

E-2 Engine maintenance -

Perkins models

E-3 Engine maintenance -

Gasoline/LPG models

E-4 Engine maintenance -

Kubota D1105 models

Perform every 3000 hours:

E-5 Engine maintenance -

Perkins models

E-6 Engine maintenance -

Kubota D1105 models

Y N R

3 - 6 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

Checklist A Procedures

REV B

A-1

Inspect the Manuals and Decals

Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first.

Maintaining the operator’s and safety manuals in good condition is essential to safe machine operation. Manuals are included with each machine and should be stored in the container provided in the platform. An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition.

In addition, maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation. Decals alert operators and personnel to the many possible hazards associated with using this machine. They also provide users with operation and maintenance information. An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions.

1 Check to make sure that the operator's and safety manuals are present and complete in the storage container on the platform.

2 Examine the pages of each manual to be sure that they are legible and in good condition.

Result: The operator's manual is appropriate for the machine and all manuals are legible and in good condition.

Result: The operator's manual is not appropriate for the machine or all manuals are not in good condition or is illegible. Remove the machine from service until the manual is replaced.

3 Open the operator's manual to the decals inspection section. Carefully and thoroughly inspect all decals on the machine for legibility and damage.

Result: The machine is equipped with all required decals, and all decals are legible and in good condition.

Result: The machine is not equipped with all required decals, or one or more decals are illegible or in poor condition. Remove the machine from service until the decals are replaced.

4 Always return the manuals to the storage container after use.

Note: Contact your authorized Genie distributor or

Genie Industries if replacement manuals or decals are needed.

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 7

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST A PROCEDURES REV B

A-2

Perform Pre-operation Inspection

Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first.

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.

Complete information to perform this procedure is available in the appropriate operator's manual.

Refer to the Operator's Manual on your machine.

A-3

Perform Function Tests

Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes first.

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.

3 - 8 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST A PROCEDURES

A-4

Perform Engine Maintenance

Engine specifications require that this procedure be performed every 8 hours or daily, whichever comes first.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5) OR the

Kubota DF752 Operator's Manual

(Kubota part number EG601-8916-1) OR the

Perkins 403D-11 User's Handbook

(Perkins part number SEBU8311-01) OR the

Perkins 403C-11 User's Handbook

(Perkins part number 100816460).

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

Kubota DF752 Operator's Manual

Genie part number

Perkins 403D-11 User's Handbook

Genie part number

Perkins 403C-11 User's Handbook

Genie part number 97360

A-5

Inspect the Engine Air Filter

131379

84240

84250

Genie specifications require that this procedure be performed every 40 hours or weekly, whichever comes first.

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.

1 Kubota D1105 and 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.

2 Kubota D1105 and D905 models: Remove the wingnut securing the end cap to the air cleaner canister. Remove the end cap.

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.

131661

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 9

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST A PROCEDURES REV B

6 Inspect the air filter element. If needed, blow from the inside out using low pressure dry compressed air, or carefully tap out dust.

7 Securely install the filter element into the canister.

8 Install the gasket and baffle (if equipped), and end cap onto the air cleaner canister.

Note: Be sure the dust discharge valve is facing down when installed.

9 Secure the end cap to the air cleaner cannister with the retaining clamps.

10 Kubota D1105 and D905 models: Swing the engine pivot tray back to its original position and make sure the engine tray locking pin locks into place.

A-6

Perform 30 Day Service

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.

1 Perform the following maintenance procedures:

Kubota models:

· B-3 Inspect the Tires, Wheels and

Lug Nut Torque

· D-2 Replace the Hydraulic Tank

Return Filter

Perkins models:

· B-3

· B-4

· C-4

· D-2

Inspect the Tires, Wheels and

Lug Nut Torque

Perform Engine Maintenance -

Perkins Models

Perform Engine Maintenance -

Diesel Models

Replace the Hydraulic Tank

Return Filter

3 - 10 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST A PROCEDURES

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 D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5).

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

A-8

Perform Engine Maintenance -

Kubota Models

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 D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5) OR the

Kubota DF752 Operator's Manual

(Kubota part number EG601-8916-1).

131379

84240

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

Kubota DF752 Operator's Manual

Genie part number

131379

84240

84250

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 11

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST A PROCEDURES REV B

A-9

Perform Engine Maintenance -

Kubota Models

Engine specifications require that this procedure be performed every 100 hours.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5) OR the

Kubota DF752 Operator's Manual

(Kubota part number EG601-8916-1).

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

Kubota DF752 Operator's Manual

Genie part number

A-10

Perform Engine Maintenance -

Kubota Models

Engine specifications require that this procedure be performed every 200 hours.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5) OR the

Kubota DF752 Operator's Manual

(Kubota part number EG601-8916-1).

131379

84240

84250

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

Kubota DF752 Operator's Manual

Genie part number

131379

84240

84250

3 - 12 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST A PROCEDURES

A-11

Drain the Fuel Filter/ Water

Separator - Diesel Models

Genie specifications require that this procedure be performed every 200 hours or monthly, whichever comes first.

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.

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.

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.

a b c d e a head bolt b vent plug c separator head d filter bowl e drain plug

3 Tighten the vent plug and clean up any spills or wet surfaces.

Note: 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.

Bleed the fuel system:

Note: Before bleeding the system, fill the fuel tank.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 13

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST A PROCEDURES REV B

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.

9 Clean up any fuel that may have spilled.

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.

Note: Information to perform this procedure is also available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5) OR the

Perkins 403D-11 User's Handbook

(Perkins part number SEBU8311-01) OR the

Perkins 403C-11 User's Handbook

(Perkins part number 100816460).

A-12

Perform Engine Maintenance -

Kubota Models

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 D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5).

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

131379

84240

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

Perkins 403D-11 User's Handbook

Genie part number

Perkins 403C-11 User's Handbook

Genie part number

131379

84240

131661

97360

3 - 14 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

Checklist B Procedures

REV B

B-1

Inspect the Battery

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

Proper battery condition is essential to good machine performance and operational safety.

Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions.

Electrocution/burn hazard. Contact with electrically charged 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.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections are free of corrosion.

Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables.

3 Be sure that the battery retainers and cable connections are tight.

4 Fully charge the battery. Allow the battery to rest 24 hours before performing this procedure to allow the battery cells to equalize.

5 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results.

6 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows:

• Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display an adjusted specific gravity of 1.277 or higher. The battery is fully charged. Proceed to step 10.

Result: One or more battery cells display a specific gravity of 1.217 or below. Proceed to step 7.

7 Perform an equalizing charge OR fully charge the batteries and allow the battery to rest at least 6 hours.

8 Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer. Note the results.

9 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows:

• Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C.

• Subtract 0.004 from the reading of each cell for every 10° / 5.5° C below 80° F / 26.7° C.

Result: All battery cells display a specific gravity of 1.277 or greater. The battery is fully charged.

Proceed to step 10.

Result: The difference in specific gravity readings between cells is greater than 0.1 OR the specific gravity of one or more cells is less than 1.217. Replace the battery.

10 Check the battery acid level. If needed, replenish with distilled water to 1 /

8

inch / 3 mm below the bottom of the battery fill tube. Do not overfill.

11 Install the vent caps and neutralize any electrolyte that may have spilled.

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 15

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST B PROCEDURES REV B

B-2

Inspect the Electrical Wiring

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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/burn 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:

· Ground control panel

· Hydraulic tray

· Engine tray

· Scissor arms

· Platform controls

2 Inspect for a liberal coating of dielectric grease in the following locations:

· Between the ECM and platform controls

· All wire harness connectors

· Level sensor

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:

· ECM to platform controls

· Power to platform wiring

9 Raise the platform and return the safety arm to the stowed position.

10 Lower the platform to the stowed position and turn the machine off.

3 - 16 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST B PROCEDURES

B-3

Inspect the Tires, Wheels and

Lug Bolt Torque

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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.

3 Remove the castle nut lock plate or cotter pin and check each castle nut for proper torque.

Refer to Section 2, Specifications.

Note: 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.

B-4

Perform Engine Maintenance -

Perkins 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 403D-11 User's Handbook

(Perkins part number SEBU8311-01) OR the

Perkins 403C-11 User's Handbook

(Perkins part number 100816460).

Perkins 403D-11 User's Handbook

Genie part number

Perkins 403C-11 User's Handbook

Genie part number

131661

97360

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 17

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST B PROCEDURES REV B

B-5

Test the Key Switch

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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.

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 .

3 Check the platform up/down function from the ground controls .

Result: The machine functions should not operate.

4 Turn the key switch to ground control .

5 Check the machine functions from the platform controls .

Result: The machine functions should not operate.

6 Turn the key switch to the

OFF

position.

Result: The engine should stop and no functions should operate.

B-6

Test the Emergency Stop

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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.

Note: As a safety feature, selecting and operating the ground controls will override the platform controls, except the platform red Emergency Stop button.

1 Start the engine from ground controls.

2 Push in the red Emergency Stop button to the off position.

Result: The engine should shut off and no machine functions should operate.

3 Start the engine from platform controls.

4 Push in the red Emergency Stop button to the off position.

Result: The engine should shut off and no machine functions should operate.

Note: 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 - 18 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST B PROCEDURES

B-7

Test the Automotive-style Horn

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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.

Note: If necessary, the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn.

B-8

Test the Fuel Select Operation -

Gasoline/LPG Models

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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.

Note: Perform this test after checking the gasoline and LPG fuel levels, and warming the engine to normal operating temperature.

Note: Be sure that the valve on the LPG tank is in the

OPEN

position.

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. 112657 GS-2668 RT • GS-3268 RT 3 - 19

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST B PROCEDURES REV B

4 Press the high idle button again to return the engine to low idle.

Result: The high idle indicator light should turn

OFF

and the engine should return to low idle.

5 Press the engine stop button.

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.

Note: 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.

B-9

Test the Drive Brakes

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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.

1 Mark a test line on the ground for reference.

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. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST B PROCEDURES

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.

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. Refer to Section

2, Specifications.

Note: The brakes must be able to hold the machine on any slope it is able to climb.

B-10

Test the Drive Speed -

Stowed Position

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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.

1 Create start and finish lines by marking two lines on the ground 40 feet / 12.2 m apart.

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.

3 Start the engine from the platform controls.

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.

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.

7 Continue at full speed and note the time when the machine reference point passes over the finish line. Refer to Section 2, Specifications.

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.

9 Continue at full speed and note the time when the machine reference point passes over the finish line. Refer to Section 2, Specifications.

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 21

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST B PROCEDURES REV B

B-11

Test the Drive Speed -

Raised Position

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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.

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.

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.

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.

Note: If the raised drive speed does not meet specifications, refer to the Repair procedure 7-2,

Function Speed Tuning.

B-12

Inspect the Fuel and Hydraulic

Tank Cap Venting Systems

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Perform this procedure more often if dusty conditions exist.

Free-breathing fuel and hydraulic tank caps are essential for good machine performance and service life. A dirty or clogged tank cap may cause the machine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the caps 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.

1 Remove the cap from the fuel tank.

2 Check for proper venting.

Result: Air passes through the fuel tank cap.

Proceed to step 4.

Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 3.

Note: When checking for positive tank cap venting, air should pass freely through the cap.

3 - 22 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST B PROCEDURES

3 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure compressed air. Repeat this procedure beginning with 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 fuel tank cap.

Proceed to step 8.

Result: If air does not pass through the cap, clean or replace the cap. Proceed to step 7.

Note: When checking for positive 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 this procedure beginning with step 6.

8 Install the breather cap onto the hydraulic tank.

B-13

Perform Hydraulic Oil Analysis

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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.

Note: 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.

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 23

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST B PROCEDURES REV B

B-14

Test the Flashing Beacons

(if equipped)

Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first.

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 Models

Engine specifications require that this procedure be performed every 400 hours.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5).

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

131379

84240

3 - 24 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

Checklist C Procedures

REV B

C-1

Test the

Platform Overload System

(if equipped)

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.

1 Disconnect the platform controls from the machine at the platform.

2 Open the ground control panel and locate the

Electronic Control Module (ECM).

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.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT

10 Fully raise the platform. Release the joystick.

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.

Result: The engine does not stop OR an alarm doesn't sound OR fault code 99 is not present in the ECM diagnostic display window at the ground controls. Refer to Repair Procedure

15-1, Calibrate the Platform Overload System

(if equipped).

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.

15 Securely connect the white wire of the maximum height limit switch wire harness to terminal B9 of the terminal strip.

16 Turn the key switch to platform control.

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.

Result: The engine stops OR an alarm sounds.

Refer to Repair Procedure 15-1, Calibrate the

Platform Overload System (if equipped).

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.

3 - 25

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST C PROCEDURES REV B

C-2

Clean the Fuel Tank -

Diesel Models

Genie requires that this procedure be performed every 500 hours or six months, whichever comes first.

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.

Note: Immediately clean up any fuel that may have spilled during this procedure.

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.

3 Using an approved hand-operated pump, drain the fuel tank into a suitable container. Refer to

Section 2, Specifications, for tank capacity.

Explosion and fire hazard. When transferring fuel, connect a grounding wire between the machine and pump or container.

Note: 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

Fuel tank retaining fasteners, lubricated

175 in-lbs

19.8 Nm

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. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST C PROCEDURES

C-3

Replace the Hydraulic Tank

Breather Cap - Models with

Optional Hydraulic Oil

C-4

Perform Engine Maintenance -

Diesel Models

Genie requires that this procedure be performed every 500 hours or six months, whichever comes first.

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.

2 Install and new cap onto the tank.

Engine specifications require that this procedure be performed every 500 hours.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5) OR the

Perkins 403D-11 User's Handbook

(Perkins part number SEBU8311-01) OR the

Perkins 403C-11 User's Handbook

(Perkins part number 100816460).

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

Perkins 403D-11 User's Handbook

Genie part number

Perkins 403C-11 User's Handbook

Genie part number

131379

84240

131661

97360

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 27

Section 3 • Scheduled Maintenance Procedures

CHECKLIST C PROCEDURES

C-5

Perform Engine Maintenance -

Kubota Models

Engine specifications require that this procedure be performed every 800 hours.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5).

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

131379

84240

November 2008

REV B

3 - 28 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

Checklist D Procedures

REV B

D-1

Check the Scissor Arm Wear

Pads

Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first.

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.

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 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.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 29

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST D PROCEDURES REV B

D-2

Replace the Hydraulic Tank

Return Filter

Genie requires that this procedure be performed every 1000 hours or annually, whichever comes first.

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.

Bodily injury hazard. Beware of hot oil. Contact with hot oil may cause severe burns.

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.

Note: The hydraulic filter is mounted on the hydraulic tank.

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.

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.

3 - 30 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST D PROCEDURES

D-3

Perform Engine Maintenance -

Perkins Models

Engine specifications require that this procedure be performed every 1000 hours.

Required maintenance procedures and additional engine information is available in the

Perkins 403D-11 User's Handbook

(Perkins part number SEBU8311-01) OR the

Perkins 403C-11 User's Handbook

(Perkins part number 100816460).

Perkins 403D-11 User's Handbook

Genie part number

Perkins 403C-11 User's Handbook

Genie part number

D-4

Perform Engine Maintenance -

Kubota Models

Engine specifications require that this procedure be performed annually.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5) OR the

Kubota DF752 Operator's Manual

(Kubota part number EG601-8916-1).

131661

97360

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

Kubota DF752 Operator's Manual

Genie part number

131379

84240

84250

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 31

Section 3 • Scheduled Maintenance Procedures

CHECKLIST D PROCEDURES

D-5

Perform Engine Maintenance -

Kubota Models

Engine specifications require that this procedure be performed every 1500 hours.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5).

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

131379

84240

November 2008

REV B

3 - 32 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

Checklist E Procedures

REV B

E-1

Test or Replace the Hydraulic Oil

Genie requires that this procedure be performed every 2000 hours or two years, whichever comes first.

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.

Note: 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.

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.

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.

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.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 33

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST E PROCEDURES REV B

12 Remove the hydraulic tank from the machine.

13 Remove the suction strainers and clean them using a mild solvent.

14 Clean the inside of the hydraulic tank using a mild solvent.

15 Install the suction strainers using thread sealer on the threads.

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.

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.

E-2

Perform Engine Maintenance -

Perkins Models

Engine specifications require that this procedure be performed every 2000 hours.

Required maintenance procedures and additional engine information is available in the

Perkins 403D-11 User's Handbook

(Perkins part number SEBU8311-01) OR the

Perkins 403C-11 User's Handbook

(Perkins part number 100816460).

Perkins 403D-11 User's Handbook

Genie part number

Perkins 403C-11 User's Handbook

Genie part number

131661

97360

3 - 34 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 3 • Scheduled Maintenance Procedures

REV B CHECKLIST E PROCEDURES

E-3

Perform Engine Maintenance -

Gasoline/LPG 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).

Kubota DF750 Operator's Manual

Genie part number

Kubota DF752 Operator's Manual

Genie part number

97359

84250

E-4

Perform Engine Maintenance -

Kubota D1105 Models

Engine specifications require that this procedure be performed every two years.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166).

Kubota D1105 Operator's Manual

Genie part number 131379

Part No. 112657 GS-2668 RT • GS-3268 RT 3 - 35

Section 3 • Scheduled Maintenance Procedures November 2008

CHECKLIST E PROCEDURES REV B

E-5

Perform Engine Maintenance -

Perkins Models

Engine specifications require that this procedure be performed every 3000 hours.

Required maintenance procedures and additional engine information is available in the

Perkins 403D-11 User's Handbook

(Perkins part number SEBU8311-01) OR the

Perkins 403C-11 User's Handbook

(Perkins part number 100816460).

Perkins 403D-11 User's Handbook

Genie part number

Perkins 403C-11 User's Handbook

Genie part number

131661

97360

E-6

Perform Engine Maintenance -

Kubota D1105 Models

Engine specifications require that this procedure be performed every 3000 hours.

Required maintenance procedures and additional engine information is available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166).

Kubota D1105 Operator's Manual

Genie part number 131379

3 - 36 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

Repair Procedures

Observe and Obey:

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.

Repair any machine damage or malfunction before operating the machine.

Before Repairs Start:

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 parts are available and ready for use.

Use only Genie approved replacement parts.

Read each procedure completely and adhere to the instructions. Attempting shortcuts may produce hazardous conditions.

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

· Wheels chocked

· All external AC power supply disconnected from the machine

About This Section

Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop. Select the appropriate repair procedure after troubleshooting the problem.

Perform disassembly procedures to the point where repairs can be completed. Then 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.

Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, may result in property damage.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 1

Section 4 • Repair Procedures

Platform Controls

June 2007

REV A

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.

For further information or assistance, consult the

Genie Industries Service Department.

a b c d e

NC 1

2 a alarm H1 b red Emergency Stop button P2 c joystick controller JC1 d circuit board U3 e platform up/down toggle switch TS20 OR platform up/down and outrigger up/down toggle switch TS21

1-1

Circuit Boards

How to Remove the Platform

Controls Circuit Board

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.

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.

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.

6 Remove the platform controls circuit board retaining fasteners.

7 Remove the platform controls circuit board from the platform control box lid.

4 - 2 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

Platform Components

REV A

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.

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.

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.

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.

5 Raise the platform and return the safety arm to the stowed position.

6 Lower the platform to the stowed position and turn the machine off.

7 Remove the mounting fasteners that secure the platform controls quick disconnect plug to the platform.

8 Twist the connector to disconnect the platform controls from the plug.

9 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.

10 Remove the cover to the AC power to platform outlet. Tag and disconnect the wiring from the outlet.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

11 Pull the wiring down through the platform tube.

Component damage hazard. The

AC power to platform wiring can be damaged if it is kinked or pinched.

Note: If your machine is equipped with an air line to platform option, the air line must be disconnected from the platform before removal.

12 Support the platform with a forklift at the steer end of the machine. Do not apply any lifting pressure.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 3

Section 4 • Repair Procedures June 2007

PLATFORM COMPONENTS REV A

13 Attach a strap from the platform railings to the carriage on the forklift to support the platform.

14 Remove the retaining fasteners from the platform pivot pins at the steer end of the machine.

15 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.

16 Remove the retaining fasteners from the platform pivot pins at the non-steer end of the machine.

17 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.

18 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: 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.

2-2

Platform Extension Deck

How to Remove the Platform

Extension Deck

1 Remove the fasteners from the access cover on the side of the platform at the non-steer end of the machine.

2 Remove the fasteners from the roller wheel mount.

3 Remove the wheel roller bolt, then remove the roller wheel from the platform.

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.

9 Remove the platform controls from the platform and lay them off to the side.

10 Position a forklift at the steer end of the machine with the forks even with the bottom of the platform extension.

4 - 4 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007

REV A

11 Carefully slide the platform extension out until the platform extension makes contact with the carriage on the forklift.

12 Attach a lifting strap from the platform extension railings to the carriage on the forklift to support the platform extension.

13 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.

Section 4 • Repair Procedures

PLATFORM COMPONENTS

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 5

Section 4 • Repair Procedures

Scissor Components

June 2007

REV B

1

12

13

2

3

4

5

6

7

8

20

21

9

10

11

Steer End

1 Number 5 pivot pin (steer end)

2 Number 4 center pivot pin

3 Number 4 pivot pin (steer end)

4 Number 3 outer arm

5 Lift cylinder rod-end pivot pin

6 Number 3 pivot pin (steer end)

7 Number 2 center pivot pins (2 each)

8 Number 2 pivot pin (steer end)

9 Number 1 center pivot pin

10 Number 1 inner arm

11 Number 1 pivot pin(s) (steer end)

12 Number 5 pivot pin (non-steer end)

GS-2668

Non-steer End

13 Number 4 inner arm

14 Number 4 outer arm

15 Number 4 pivot pin (non-steer end)

16 Number 3 inner arm

17 Number 3 center pivot pin

18 Number 3 pivot pin (non-steer end)

19 Number 2 inner arm

20 Number 2 outer arm

21 Number 2 pivot pin (non-steer end)

22 Lift cylinder barrel-end pivot pin

23 Number 1 outer arm

22

23

18

19

14

15

16

17

4 - 6 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 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.

Note: 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 2, Hydraulic Hose and

Fitting Torque Specifications.

1 Remove the platform. See 2-1, How to Remove the Platform.

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.

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.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 7

Section 4 • Repair Procedures June 2007

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.

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.

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.

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.

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.

4 - 8 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 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.

36 Remove the mounting fasteners from the lower cable tray supports at both ends of the lower cable tray.

37 Remove the lower cable tray from the machine.

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.

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.

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.

45 Remove the external snap rings from the number 2 center pivot pin (index #7) at the ground controls side.

46 Use a soft metal drift to remove the number 2 center pivot pin (index #7) at the ground controls side.

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.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 9

Section 4 • Repair Procedures June 2007

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.

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.

4 - 10 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 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.

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.

Note: During removal, the lifting strap connected to the overhead crane will need to be carefully adjusted for proper balancing.

69 Remove the straps securing the scissor arms together.

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.

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.

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.

Crushing hazard. The number 1 inner arm (index #10) could become unbalanced and fall if not properly supported when removed from the machine.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 11

Section 4 • Repair Procedures June 2007

SCISSOR COMPONENTS REV B

5

6

7

8

9

10

11

1

2

3

4

12

13

14

15

Steer End

1 Number 6 pivot pin (steer end)

2 Number 5 center pivot pin

3 Upper lift cylinder rod-end pivot pin

4 Number 5 pivot pin (steer end)

5 Number 4 center pivot pins (2 each)

6 Number 4 pivot pin (steer end)

7 Number 3 outer arm

8 Number 3 center pivot pin

9 Lower lift cylinder rod-end pivot pin

10 Number 3 pivot pin (steer end)

11 Number 2 center pivot pins (2 each)

12 Number 2 pivot pin (steer end)

13 Number 1 center pivot pin

14 Number 1 inner arm

GS-3268

Non-steer End

15 Number 1 pivot pin(s) (steer end)

16 Number 6 pivot pin (non-steer end)

17 Number 5 inner arm

18 Number 5 outer arm

19 Number 5 pivot pin (non-steer end)

20 Number 4 inner arm

21 Number 4 outer arm

22 Number 4 pivot pin (non-steer end)

23 Upper lift cylinder barrel-end pivot pin

24 Number 3 inner arm

25 Number 3 pivot pin (non-steer end)

26 Number 2 inner arm

27 Number 2 outer arm

28 Number 2 pivot pin (non-steer end)

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

4 - 12 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B SCISSOR COMPONENTS

3-2

Scissor Assembly, GS-3268 RT

How to Disassemble the

Scissor Assembly, 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 required.

Note: 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 2, Hydraulic Hose and

Fitting Torque Specifications.

1 Remove the platform. See 2-1, How to Remove the Platform.

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).

5 Use a soft metal drift to remove the number 5 center pivot pin (index #2).

6 Remove the external snap rings from the number 5 pivot pin (index #19) at the non-steer end.

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.

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.

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 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.

Crushing hazard. The cylinder could fall if not properly supported when the pin is removed.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 13

Section 4 • Repair Procedures June 2007

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.

17 Remove the mounting fasteners from the upper cable tray supports at both ends of the upper cable tray.

18 Remove the upper cable tray.

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.

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.

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.

29 Remove the external snap rings from the number 4 center pivot pin (index #5) at the ground controls side.

30 Use a soft metal drift to remove the number 4 center pivot pin (index #5) at the ground controls side.

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.

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.

4 - 14 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 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.

35 Use a soft metal drift to remove the number 4 center pivot pin (index #5) at the engine side.

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.

37 Remove the external snap rings from the number 4 pivot pin (index #6) at the steer end of the machine.

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.

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.

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.

Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it 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.

43 Remove the external snap rings from the number 3 center pivot pin (index #8) at the ground controls side.

44 Use a soft metal drift to tap the number 3 center pivot pin (index #8) halfway out at the ground controls side.

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.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 15

Section 4 • Repair Procedures June 2007

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.

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.

56 Attach a lifting strap from an overhead crane to the lug on the rod end of the lower lift cylinder.

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.

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.

4 - 16 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 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.

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.

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.

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.

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.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 17

Section 4 • Repair Procedures June 2007

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.

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.

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.

Note: During removal, the lifting strap connected to the overhead crane will need to be carefully adjusted for proper balancing.

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.

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.

94 Remove the number 1 outer arm (index #30) from the assembly.

Crushing hazard. The number 1 outer arm (index #30) could become unbalanced and fall if not properly supported when removed from the machine.

4 - 18 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B SCISSOR COMPONENTS

3-3

Wear Pads

How to Replace the Scissor Arm

Wear Pads

Platform Scissor Arm Wear Pads:

1 Remove the platform. See 2-1, How to Remove the Platform.

2 Remove the wear pads from the slide blocks.

Discard the wear pads.

3 Using a mild solvent, clean the wear pad mounting surfaces of both slide blocks.

4 Use a knife or scissors to cut the provided double-sided adhesive tape to the correct length.

Component damage hazard. Use a knife or scissors to cut the tape to length. Tearing the tape will at the same time stretch the tape, reducing the adhesive quality of the tape. Do not tear the tape.

5 Remove the protective cover from the adhesive tape and install the tape, equally spaced, onto the slide block. Do not stretch the tape during installation.

Component damage hazard.

Stretching the tape will reduce the adhesive quality of the tape. Do not stretch the tape.

6 Install the wear pads onto the slide blocks.

Securely fix the adhesive tape of the slide blocks to the wear pads using firm, even hand pressure.

7 Install the platform.

Chassis Scissor Arm Wear Pads:

1 Attach a lifting strap from an overhead crane to the ladder at the non-steer end of the machine.

Support the ladder. Do not apply any lifting pressure.

2 Remove the fasteners securing the ladder to the chassis. Remove the ladder from the machine.

Crushing hazard. The ladder could fall if not properly supported when the fasteners are removed from the machine.

3 Secure both ends of the scissor arms together with a strap or other suitable device.

4 Attach a strap from an overhead crane to the non-steer end of the scissor arms.

5 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.

6 Remove the pin retaining fasteners from the slide block pivot pin.

7 Place a rod through the pin and twist to remove the pin.

8 Remove the slide block and remove the wear pad mounting fasteners.

9 Install the new wear pad. Install and securely tighten the fasteners. Do not over tighten.

10 Repeat steps 6 through 9 for the other wear pad slide block.

11 Install the wear pad slide blocks into the drive chassis and install the slide block pivot pins and pin retaining fasteners. Securely tighten the fasteners. Do not over tighten.

12 Securely install the ladder onto the machine. Do not over tighten the fasteners.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 19

Section 4 • Repair Procedures June 2007

SCISSOR COMPONENTS REV B

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

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.

Note: 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 2, Hydraulic Hose and

Fitting Torque Specifications.

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.

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic

AK

Y7

Y10

A I

Note: 'alphanumeric' callouts refer to corresponding notes on the electrical schematic a b c

GS-2668 RT a platform down solenoid valve b lift cylinder c pressure switch (CE models)

3 Lower the platform onto the safety arm.

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 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.

4 - 20 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B SCISSOR COMPONENTS

6 Attach a strap from an overhead crane or similar lifting device to the rod end of the lift cylinder for support.

7 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.

8 Lower the cylinder onto the number 1 center pivot pin.

9 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.

10 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.

11 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.

Component damage hazard. Be careful not to damage the valve or fittings on the cylinder while removing it from the machine.

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.

Note: 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 2, Hydraulic Hose and

Fitting Torque Specifications.

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.

Crushing hazard. Keep hands clear of the safety arm when lowering the platform.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 21

Section 4 • Repair Procedures June 2007

SCISSOR COMPONENTS REV B

UPPER

CYLINDER

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic

Y7A

Y10A a

A I b

LOWER

CYLINDER

AK

Y7

Y10

A I

Note: 'alphanumeric' callouts refer to corresponding notes on the electrical schematic a c d

GS-3268 RT a platform down solenoid valve b upper lift cylinder c lower lift cylinder d pressure switch (CE models)

4 Tag and disconnect the wiring from the solenoid valve at the barrel end of the lift cylinder.

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.

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.

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.

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.

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.

4 - 22 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 4 • Repair Procedures

Kubota D1105 and D905 Engines

REV C

4-1

Timing Adjustment

Complete information to perform this procedure is available in the

Kubota D1105 Workshop Manual (Kubota part number 9Y111-00123) OR the

Kubota D905 Workshop Manual (Kubota part number 97897-02432).

Kubota D1105 Workshop Manual

Genie part number

Kubota D905 Workshop Manual

Genie part number

131666

31742

4-2

Glow Plugs

How to Check the Glow Plugs

1 Connect the leads from an ohmmeter between the far left glow plug and ground.

Result: The resistance should be approximately

1

Ω.

2 If the ohm reading is different than 1

Ω

, 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.

Result: The resistance should be approximately

1.8

Ω 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. 112657 GS-2668 RT • GS-3268 RT 4 - 23

Section 4 • Repair Procedures November 2008

KUBOTA D1105 and D905 ENGINES REV C

4-3

Engine RPM

How to Adjust the RPM

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.

a b

4-4

Flex Plate

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.

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.

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.

d c a high idle solenoid b low idle adjustment screw c lock nut d 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.

4 - 24 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 4 • Repair Procedures

REV C KUBOTA D1105 and D905 ENGINES

How to Install the Flex Plate

1 Install the flex plate onto the flywheel with the raised spline toward the pump.

Note: 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.

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. Do not force the drive pump during installation or the flex plate splines may become damaged.

a b c d e f a pump b pump shaft c pump coupler d flex plate f e flywheel

1 /

32

inch / 0.8 mm gap

4-5

Coolant Temperature and Oil

Pressure Switches

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

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. 112657 GS-2668 RT • GS-3268 RT 4 - 25

Section 4 • Repair Procedures November 2008

KUBOTA D1105 and D905 ENGINES REV C

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.

Note: Always use pipe thread sealant when installing a new switch.

a b

How to Repair the Kubota

D1105 and D905 Engines

Repair procedures and additional engine information are available in the

Kubota D1105 Operator's Manual

(Kubota part number 16622-89166) OR the

Kubota D905 Operator's Manual

(Kubota part number 16622-8916-5) OR the

Kubota D1105 Workshop Manual

(Kubota part number 9Y111-00123).

Kubota D905 Workshop Manual

(Kubota part number 97897-02432).

Kubota D1105 Operator's Manual

Genie part number

Kubota D905 Operator's Manual

Genie part number

Kubota D1105 Workshop Manual

Genie part number

Kubota D905 Workshop Manual

Genie part number

131379

84240

131666

31742 a coolant temperature switch b oil pressure switch

4 - 26 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

Kubota DF752 Engine

REV A

5-1

Timing Adjustment -

Gasoline/LPG Models

Note: 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.

5-3

Choke Adjustment -

Gasoline/LPG Models

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

Note: 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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 27

Section 4 • Repair Procedures June 2007

KUBOTA DF752 ENGINE REV A

5-6

Engine RPM

How to Adjust the RPM

Note: The on-board self diagnostics incorporate a built-in engine tachometer. The first two digits of the engine rpm are displayed on the diagnostic 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.

Note: 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.

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.

a b c d a solenoid boot b threaded rod c yoke locknut d yoke

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.

Note: Be sure the solenoid fully retracts when activating high idle.

How to Repair the Kubota

DF752 Engine

Repair procedures and additional engine information are available in the

Kubota DF752 Operator's Manual

(Kubota part number EG601-8916-1) OR the

Kubota DF752 Workshop Manual

(Kubota part number 97897-02100).

Kubota DF752 Operator's Manual

Genie part number

Kubota DF752 Workshop Manual

Genie part number

84250

84249

4 - 28 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008 Section 4 • Repair Procedures

REV B

Perkins 403D-11 and 403C-11 Engines

6-1

Engine RPM

How to Adjust the RPM

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 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.

Note: Be sure the solenoid fully retracts when activating high idle.

6-2

Timing Adjustment

Complete information to perform this procedure is available in the

Perkins 403D-11 Workshop Manual (Perkins part number KENR6942) OR the

Perkins 403C-11 Workshop Manual (Perkins part number TPD1458).

Perkins 403D-11 Workshop Manual

Genie part number

Perkins 403C-11 Workshop Manual

Genie part number

131662

84817 a b c d a solenoid b yoke locknut c yoke d low idle lock nut e low idle adjustment screw e

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 29

Section 4 • Repair Procedures November 2008

PERKINS 403D-11 and 403C-11 ENGINES REV B

6-3

Flex Plate

See 4-4, Flex Plate.

6-4

Coolant Temperature and Oil

Pressure 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.

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.

A fault code will be shown in the diagnostic display window at the ground controls when either switch closes.

How to Replace the 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.

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.

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.

Note: Always use pipe thread sealant when installing a new switch.

4 - 30 GS-2668 RT • GS-3268 RT Part No. 112657

November 2008

REV B

How to Repair the Perkins

403D-11 and 403C-11 Engines

Repair procedures and additional engine information are available in the

Perkins 403D-11 User's Handbook

(Perkins part number SEBU8311-01) OR the

Perkins 403D-11 Workshop Manual

(Perkins part number KENR6942) OR the

Perkins 403C-11 User's Handbook

(Perkins part number 100816460) OR the

Perkins 403C-11 Workshop Manual

(Perkins part number TPD1458).

Perkins 403D-11 Operator's Manual

Genie part number

Perkins 403D-11 Workshop Manual

Genie part number

Perkins 403C-11 Operator's Manual

Genie part number

Perkins 403C-11 Workshop Manual

Genie part number

131661

131662

97360

84817

Section 4 • Repair Procedures

PERKINS 403D-11 and 403C-11 ENGINES

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 31

Section 4 • Repair Procedures

Ground Controls

June 2007

REV B

7-1

Auxiliary Platform Lowering

Auxiliary Platform Lowering

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.

The auxiliary platform lowering circuit uses the main 12V battery for its power source.

7-2

Function Speed Tuning

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

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.

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.

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.

4 - 32 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B GROUND CONTROLS

How to Adjust the

Stowed Drive Speed

Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than specifications could cause the machine to tip over resulting in death or serious injury.

1 Pull out the red Emergency Stop button to the on position at the platform controls.

2 Push in the red Emergency Stop button to the off position at the ground controls.

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 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.

a d a diagnostic display b blue platform up button c lift function enable button d yellow platform down button

9 Press the lift function enable button.

Result:

TUNE SPEEDS

is showing in the diagnostic display window. The ECM is now in programming mode.

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.

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.

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.

b c

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 33

Section 4 • Repair Procedures June 2007

GROUND CONTROLS REV B

How to Adjust the

High Torque Drive Speed

Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than specifications could cause the machine to tip over resulting in death or serious injury.

1 Pull out the red Emergency Stop button to the on position at the platform controls.

2 Push in the red Emergency Stop button to the off position at the ground controls.

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.

a d a diagnostic display b blue platform up button c lift function enable button d yellow platform down button

9 Press the lift function enable button.

Result:

TUNE SPEEDS

is showing in the diagnostic display window. The ECM is now in programming mode.

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.

14 Press the lift function enable button.

15 Push in the red Emergency Stop button to the off position at the ground controls.

b c

4 - 34 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B GROUND CONTROLS

How to Adjust the

Raised Drive Speed

Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than specifications could cause the machine to tip over resulting in death or serious injury.

1 Pull out the red Emergency Stop button to the on position at the platform controls.

2 Push in the red Emergency Stop button to the off position at the ground controls.

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 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.

a d a diagnostic display b blue platform up button c lift function enable button d yellow platform down button

9 Press the lift function enable button.

Result:

TUNE SPEEDS

is showing in the diagnostic display window. The ECM is now in programming mode.

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.

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.

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.

b c

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 35

Section 4 • Repair Procedures June 2007

GROUND CONTROLS REV B

How to Adjust the

Lift Speed

1 Pull out the red Emergency Stop button to the on position at the platform controls.

2 Push in the red Emergency Stop button to the off position at the ground controls.

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 lift speed.

Result:

MAX LIFT SPEED

is showing in the diagnostic display window.

7 Press the lift function enable button.

a a diagnostic display b blue platform up button c lift function enable button d yellow platform down button

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.

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.

d b c

4 - 36 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B

7-3

Software Configuration

How to Configure the Software

The Electronic Control Module (ECM) contains programming for all configurations of the GS-68.

Machines can be adjusted to a different configuration using the buttons at the ground controls. To determine the software revision level, see 7-2, How to Determine the Revision Level.

ANSI and CSA models with all software revisions:

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. Note the result.

2 Push in the red Emergency Stop button to the off position at the ground controls.

3 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 diagnostic display b blue platform up button c lift function enable button d yellow platform down button

GROUND CONTROLS

Machine Option Definitions

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.

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.

Motion Alarm: The motion alarm will sound when activating a function.

Motion Beacons: The flashing beacons operate only when activating a function.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 37

Section 4 • Repair Procedures June 2007

GROUND CONTROLS REV B

4 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.

5 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.

6 Models with software revisions F0, E0, D0 and lower: 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.

Note: 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 beacon.

Result:

MOTION BEACON

is showing in the diagnostic display window.

9 Press the lift function enable button to activate or deactivate the motion beacon option.

Note: 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.

Note: For all models except CE, the sim operation option should be activated or in the

ON

position.

Models with software revisions E0, D0 or lower, proceed to step 12.

Models with software revisions F0 and higher, proceed to step 15.

12 Use the yellow platform down arrow to scroll to beacons option.

Result:

BEACONS AUTO

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the beacons option.

Note: For this option to function, the machine must be equipped with flashing beacons and the software set to

BEACONS AUTO

or

BEACONS ON

.

4 - 38 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B GROUND CONTROLS

13 Use the yellow platform down arrow to scroll to generator option.

Result:

GENERATOR AUTO

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the generator option.

Note: For this option to function correctly, the machine must be equipped with the required generator components and the software set to

GENERATOR AUTO

or

GENERATOR ON

.

14 Use the yellow platform down arrow to scroll to outriggers option.

Result:

OUTRIGGERS AUTO

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the outrigger option. Proceed to step 18.

Note: For this option to function correctly, the machine must be equipped with the required outrigger components and the software set to

OUTRIGGERS AUTO

or

OUTRIGGERS ON

.

15 Use the yellow platform down arrow to scroll to beacons option.

Result:

BEACONS OFF

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the beacons option.

Note: For this option to function, the machine must be equipped with flashing beacons.

16 Use the yellow platform down arrow to scroll to generator option.

Result:

GENERATOR OFF

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the generator option.

Note: For this option to function correctly, the machine must be equipped with the required generator components.

17 Use the yellow platform down arrow to scroll to outriggers option.

Result:

OUTRIGGERS OFF

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the outrigger option.

Note: For this option to function correctly, the machine must be equipped with the required outrigger components.

ANSI and CSA models with all software revisions:

18 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.

19 Press the lift function enable button.

Result:

SELECT OPTIONS

is showing in the diagnostic display window.

20 Push in the red Emergency Stop button to the off position at the ground controls.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 39

Section 4 • Repair Procedures June 2007

GROUND CONTROLS REV B

CE models with all software revisions:

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. Note the result.

2 Push in the red Emergency Stop button to the off position at the ground controls.

3 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 b c a diagnostic display b blue platform up button c lift function enable button d yellow platform down button d

4 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.

5 Press the lift function enable button.

Result:

DESCENT DELAY ON

is showing in the diagnostic display window.

Result:

DESCENT DELAY OFF

is showing in the diagnostic display window. Press the lift function enable button to activate the descent delay option.

Note: For CE models, the descent delay option should be activated or in the

ON

position.

6 Models with software revisions F0, E0, D0 and lower: 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.

Note: 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 beacon.

Result:

MOTION BEACON

is showing in the diagnostic display window.

4 - 40 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B GROUND CONTROLS

9 Press the lift function enable button to activate or deactivate the motion beacon option.

Note: For this option to function correctly, the machine must be equipped with flashing beacons.

10 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.

Note: 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.

Note: For CE models, the sim operation option should be deactivated or in the

OFF

position.

Models with software revisions E0, D0 or lower, proceed to step 12.

Models with software revisions F0 and higher, proceed to step 15.

12 Use the yellow platform down arrow to scroll to beacons option.

Result:

BEACONS AUTO

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the beacons option.

Note: For this option to function, the machine must be equipped with flashing beacons and the software set to

BEACONS AUTO

or

BEACONS ON

.

13 Use the yellow platform down arrow to scroll to generator option.

Result:

GENERATOR AUTO

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the generator option.

Note: For this option to function correctly, the machine must be equipped with the required generator components and the software set to

GENERATOR AUTO

or

GENERATOR ON

.

14 Use the yellow platform down arrow to scroll to outriggers option.

Result:

OUTRIGGERS AUTO

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the outrigger option. Proceed to step 18.

Note: For this option to function correctly, the machine must be equipped with the required outrigger components and the software set to

OUTRIGGERS AUTO

or

OUTRIGGERS ON

.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 41

Section 4 • Repair Procedures June 2007

GROUND CONTROLS REV B

15 Use the yellow platform down arrow to scroll to beacons option.

Result:

BEACONS OFF

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the beacons option.

Note: For this option to function, the machine must be equipped with flashing beacons.

16 Use the yellow platform down arrow to scroll to generator option.

Result:

GENERATOR OFF

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the generator option.

Note: For this option to function correctly, the machine must be equipped with the required generator components.

17 Use the yellow platform down arrow to scroll to outriggers option.

Result:

OUTRIGGERS OFF

is showing in the diagnostic display window. Press the lift function enable button to activate or deactivate the outrigger option.

Note: For this option to function correctly, the machine must be equipped with the required outrigger components.

CE models with all software revisions:

18 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.

19 Press the lift function enable button.

Result:

SELECT OPTIONS

is showing in the diagnostic display window.

20 Push in the red Emergency Stop button to the off position at the ground controls.

4 - 42 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B GROUND CONTROLS

7-4

Level Sensor -

Models without Outriggers

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 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.

Note: 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.

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 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 a level sensor b max height limit switch (CE models) c down limit switch d 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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 43

Section 4 • Repair Procedures June 2007

GROUND CONTROLS REV B

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.

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.

Note: Be sure there are threads showing through the top of the adjusting fasteners.

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.

a b

Y

X

MODELS

WITHOUT

OUTRIGGERS

Level sensor - models without outriggers a chassis b level sensor c "X" indicator d "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.

d c

4 - 44 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B

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.

21 Raise the machine slightly.

22 Remove the blocks from under both wheels.

23 Lower the machine and remove the jack.

24 Center a lifting jack under the drive chassis at the engine side of the machine.

25 Raise the machine approximately

4 inches / 10 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.

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.

27 Lower the machine onto the blocks.

GROUND CONTROLS

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.

30 Push in the red Emergency Stop button to the off position at both the ground and platform controls.

31 Turn the key switch to the off position.

32 Raise the machine slightly.

33 Remove the blocks from under both wheels.

34 Lower the machine and remove the jack.

35 Install the cover onto the level sensor enclosure. Install and securely tighten the retaining fasteners. Do not over tighten.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 45

Section 4 • Repair Procedures June 2007

GROUND CONTROLS REV B

7-5

Level Sensor -

Models with Outriggers

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.

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.

Note: 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.

If you are not installing a new level sensor, proceed to step 7.

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 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 a level sensor b max height limit switch (CE models) c down limit switch d load sense delay limit switch (CE models)

Install the level sensor:

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.

4 - 46 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B GROUND CONTROLS

8 Install the new level sensor onto the machine with the "X" on the level sensor base closest to the steer end of the machine. Install and tighten the level sensor retaining fasteners.

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.

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 Set a multimeter to read DC voltage.

Adjust the side-to-side axis:

12 Without disconnecting the wire harness from the level sensor, connect the negative lead of the multimeter to the black wire at the level sensor.

13 Without disconnecting the wire harness from the level sensor, connect the positive lead of the multimeter to the yellow wire at the level sensor.

14 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.

Note: Be sure there are threads showing through the top of each adjusting nut.

a b

X

Y

MODELS

WITH

OUTRIGGERS

Level sensor - models without outriggers a chassis b level sensor c "Y" indicator d "X" indicator

15 Disconnect the positive lead.

Adjust the front-to-back axis:

16 Without disconnecting the wire harness from the level sensor, connect the positive lead of the multimeter to the blue wire at the level sensor.

d c

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 47

Section 4 • Repair Procedures June 2007

GROUND CONTROLS REV B

17 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.

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.

Note: Be sure there are threads showing through the top of each adjusting nut.

18 Disconnect the positive and negative leads.

19 Apply Sentry Seal to the adjusting nuts.

20 Push in the red Emergency Stop button to the off position at the platform controls.

21 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.

22 Push in the red Emergency Stop button to the off position at the platform controls.

Confirm the side-to-side level sensor setting:

23 Center a lifting jack under the drive chassis at the ground control side of the machine.

24 Raise the machine approximately

6 inches / 15 cm.

25 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.

26 Lower the machine onto the blocks.

27 Pull out the red Emergency Stop button to the on position at platform controls. Start the engine.

28 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.

Note: 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.

29 Raise the machine slightly.

30 Remove the blocks from under both wheels.

31 Lower the machine and remove the jack.

32 Center a lifting jack under the drive chassis at the tank side of the machine.

33 Raise the machine approximately

6 inches / 15 cm.

34 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 Lower the machine onto the blocks.

4 - 48 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B GROUND CONTROLS

36 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.

Note: 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.

37 Lower the platform to the stowed position.

38 Raise the machine slightly.

39 Remove the blocks from under both wheels.

40 Lower the machine and remove the jack.

Confirm the front-to-back level sensor setting:

41 Center a lifting jack under the drive chassis at the steer end of the machine.

42 Raise the machine approximately

6 inches / 15 cm.

43 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.

44 Lower the machine onto the blocks.

45 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.

Note: 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.

46 Lower the platform to the stowed position.

47 Raise the machine slightly.

48 Remove the blocks from under both wheels.

49 Lower the machine and remove the jack.

50 Center a lifting jack under the drive chassis at the non-steer end of the machine.

51 Raise the machine approximately

6 inches / 15 cm.

52 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.

53 Lower the machine onto the blocks.

54 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.

Note: 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.

55 Lower the platform to the stowed position.

56 Raise the machine slightly.

57 Remove the blocks from under both wheels.

58 Lower the machine and remove the jack.

59 Turn the key switch to the off position.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 49

Section 4 • Repair Procedures

Hydraulic Pump

June 2007

REV A

8-1

Hydraulic 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.

Note: 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 2, 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.

2 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to the high pressure port on each section of the pump.

3 Gasoline/LPG models: Disconnect the ignition coil wire from the center of the ignition coil.

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.

4 - 50 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV A HYDRAULIC PUMP

How to Remove the

Hydraulic Pump

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 and drive speed settings to original factory specifications.

Refer to Section 3, Scheduled

Maintenance Procedures.

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 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. 112657 GS-2668 RT • GS-3268 RT 4 - 51

Section 4 • Repair Procedures

Manifolds

June 2007

REV B

9-1

Function Manifold Components

The function manifold is located inside the hydraulic tray.

6

7

8

9

Index

No.

1

2

3

4

5

10

11

12

13

14

Description

Schematic

Item Function Torque

Relief valve, 3500 psi / 241.3 bar ........ FA ....... Anti-cavitation for rear drive circuit ... 15-25 ft-lbs / 20-34 Nm

Solenoid valve,

2 position 2 way N.C. .......................... FB ....... Drive speed select circuit at the non-steer end of the machine ........... 25-30 ft-lbs / 34-41 Nm

Orifice - plug, 0.030 in / 0.76 mm ........ FC ....... Balances flow from flow divider/combiner (item FAE) to non-steer end drive motors

Solenoid valve,

2 position 4 way N.O. .......................... FD ....... Drive speed select circuit at the non-steer end of the machine ........... 25-30 ft-lbs / 34-41 Nm

Solenoid valve, 3 position 4 way ......... FE ....... Controls flow to the non-steer end drive motors in forward and reverse ....................................... 25-30 ft-lbs / 34-41 Nm

Solenoid valve, 3 position 4 way ......... FF ....... Steer left/right .................................... 25-30 ft-lbs / 34-41 Nm

Check valve ......................................... FG ....... Proportional circuit ............................ 25-30 ft-lbs / 34-41 Nm

Check valve ......................................... FH ....... Proportional circuit ............................ 25-30 ft-lbs / 34-41 Nm

Orifice - plug, 0.030 in / 0.76 mm ........ FI ........ Balances flow from flow divider/combiner (item FM) to steer end drive motors

Orifice - plug, 0.035 in / 0.89 mm ........ FJ ........ Controls brake release speed

Solenoid valve,

2 position 2 way N.C. .......................... FK ....... Drive speed select circuit at the steer end of the machine .................. 25-30 ft-lbs / 34-41 Nm

Relief valve, 3500 psi / 241.3 bar ........ FL ....... Anti-cavitation for front drive circuit .. 15-25 ft-lbs / 20-34 Nm

Flow divider/combiner valve ................ FM ...... Controls flow to the steer end drive motors in forward and reverse ..... 30-35 in-lbs / 3-4 Nm

Check valve ......................................... FN ....... Steer end drive circuit ....................... 25-30 ft-lbs / 34-41 Nm

This list continues. Please turn the page.

4 - 52 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

31

FAE

30

FAD

29

FAC

FAB

28

FAA

27

26

FZ

25

FY

FX

24

23

FW

REV B MANIFOLDS

Y1

FA

FB

FC

FD

FE

FD

Y6

Y1A

Y5

Y3

Y4

Y9

Y8

Y6A

Y5A

Y2

FF

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic

6

Note: 'alphanumeric' callouts refer to corresponding notes on the electrical schematic

FG

7

4

5

1

2

3

22

FV

21

FU

FT

20

19

FS

18

FR

Part No. 112657

Y5

Y6

Y1A

Y9

Y4

Y3

Y8

Y2

Y5A

Y6A

Y1B

17

FQ

16

FP

15

FO

Y1.1

FN

14

FM

13

FL

12 11

FK

GS-2668 RT • GS-3268 RT

FH

8

F I

FJ

9

10

4 - 53

Section 4 • Repair Procedures June 2007

MANIFOLDS REV B

Function Manifold Components, continued

26

27

28

19

20

21

22

23

Index

No.

15

16

17

18

24

25

29

30

31

Description

Schematic

Item Function Torque

Priority flow regulator,

2 gpm / 7.6 L/min ................................. FO ....... Steer circuit ....................................... 25-30 ft-lbs / 34-41 Nm

Solenoid valve, 2 position 3 way ......... FP ....... Brake circuit ...................................... 20-25 ft-lbs / 27-54 Nm

Solenoid valve,

2 position 4 way N.O. .......................... FQ ....... Drive speed select circuit at the steer end of the machine .................. 25-30 ft-lbs / 34-41 Nm

Solenoid valve, 3 position 4 way ......... FR ....... Controls flow to the steer end drive motors in forward and reverse .............................................. 25-30 ft-lbs / 34-41 Nm

Relief valve, 3500 psi / 241 bar ........... FS ....... Lift circuit ........................................... 15-25 ft-lbs / 20-34 Nm

Solenoid valve, 2 position 4 way ......... FT ....... Platform up ........................................ 25-30 ft-lbs / 34-41 Nm

Proportional solenoid valve N.O. ........ FU ....... Drive/lift circuit .................................. 25-30 ft-lbs / 34-41 Nm

Relief valve, 2800 psi / 193 bar ........... FV ....... Steer left/right .................................... 25-30 ft-lbs / 34-41 Nm

Counterbalance valve,

1000 psi / 68.9 bar ............................... FW ...... Improves braking performance ......... 30-35 ft-lbs / 41-47 Nm

Diagnostic nipple - Test port #2 .......... FX ....... Testing

Relief valve, 3000 psi / 207 bar ........... FY ....... Relief valve for number two section of pump .......................... 15-25 ft-lbs / 20-34 Nm

Check valve ......................................... FZ ....... Steer circuit ....................................... 25-30 ft-lbs / 34-41 Nm

Diagnostic nipple - Test port #1 .......... FAA ..... Testing

Counterbalance valve,

2500 psi / 172 bar ................................ FAB ..... Improves braking performance ......... 30-35 ft-lbs / 41-47 Nm

Relief valve, 3500 psi / 241 bar ........... FAC .... Relief valve for number one section of pump ......................... 15-25 ft-lbs / 20-34 Nm

Check valve ......................................... FAD .... Non-steer end drive circuit ................ 25-30 ft-lbs / 34-41 Nm

Flow divider/combiner valve ................ FAE ..... Controls flow to the non-steer end drive motors in forward and reverse ..... 30-35 in-lbs / 3-4 Nm

4 - 54 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

31

FAE

30

FAD

29

FAC

FAB

28

FAA

27

26

FZ

25

FY

FX

24

23

FW

REV B MANIFOLDS

Y1

FA

FB

FC

FD

FE

FD

Y6

Y1A

Y5

Y3

Y4

Y9

Y8

Y6A

Y5A

Y2

FF

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic

6

Note: 'alphanumeric' callouts refer to corresponding notes on the electrical schematic

FG

7

4

5

1

2

3

22

FV

21

FU

FT

20

19

FS

18

FR

Part No. 112657

Y5

Y6

Y1A

Y9

Y4

Y3

Y8

Y2

Y5A

Y6A

Y1B

17

FQ

16

FP

15

FO

Y1.1

FN

14

FM

13

FL

12 11

FK

GS-2668 RT • GS-3268 RT

FH

8

F I

FJ

9

10

4 - 55

Section 4 • Repair Procedures June 2007

MANIFOLDS REV B

9-2

Valve Adjustments -

Function Manifold

How to Adjust the System Relief

Valves

The function manifold contains two system relief valves, one for each section of the pump.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to test port #2 (item FX) and test port #1

(item FAA) on the function manifold.

2 Place wheel chocks in front of all four wheels.

3 Remove the platform controls from the platform and place the controls near the function manifold on the tank side of the machine.

4 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.

6 Turn the engine off. Use a wrench to hold the

P2 system relief valve (item FY) or P1 system relief valve (item FAC) and remove the cap .

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 this procedure beginning with step 4 to confirm the relief valve pressures.

a

FAC b

FAA

FY c d

FX a P1 system relief valve b test port #1 c test port #2 d P2 system relief valve

4 - 56 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B

How to Adjust the Steer Relief

Valve

1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to test port #1 (item FAA) on the function manifold.

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.

3 Start the engine from the platform controls.

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 FV).

6 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap.

Component damage hazard. Do not adjust the relief valve higher than specified.

7 Repeat this procedure beginning with step 3 to confirm the relief valve pressure.

a

FAA b

FV a test port #1 b steer relief valve

MANIFOLDS

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 57

Section 4 • Repair Procedures

MANIFOLDS

How to Adjust the

Lift Relief Valve

Note: Be sure that the hydraulic oil level is within the top 2 inches / 5 cm of the sight gauge.

1 Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to test port #2 (item FX) on the function manifold.

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.

4 Start the engine from the ground controls.

5 Press and hold the lift function enable button and move the platform up/down toggle switch in the up direction. Allow the platform to raise completely, then continue activating the lift function while observing the pressure reading on the pressure gauge. Note the pressure.

Refer to Section 2, Specifications.

6 Turn the engine off. Hold the lift relief valve with a wrench and remove the cap (item FS).

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 this procedure beginning with step 4 to confirm the relief valve pressure.

a

FX b

FS a test port #2 b lift relief valve

June 2007

REV B

4 - 58 GS-2668 RT • GS-3268 RT Part No. 112657

4

3

June 2007 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

2

3

Index

No.

1

4

Description

Schematic

Item Function Torque

Relief valve, 2000 psi / 137.8 bar ......... BA ......... Outrigger circuit ..................................... 20 ft-lbs / 27.1 Nm

Solenoid valve, 2 position 2 way .......... BB ......... Outrigger slow extend .............................. 25 ft-lbs / 34 Nm

Orifice - plug,

0.063 inch / 1.6 mm .............................. BC ......... Outrigger retract

Solenoid valve, 3 position 4 way .......... BD ......... Outrigger extend/retract ........................... 25 ft-lbs / 34 Nm

1

BA

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic

Note: 'alphanumeric' callouts refer to corresponding notes on the electrical schematic

BD Y40

Y39

BC

Y44

BB

2

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 59

Section 4 • Repair Procedures June 2007

MANIFOLDS REV B

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.

Note: 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 2, Hydraulic Hose and

Fitting Torque Specifications.

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.

3 Connect the platform controls to the quick disconnect plug above the hydraulic tank.

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.

Note: The

IN

port of the outrigger manifold is located next to the outrigger extend/retract valve

(item BD) and is labeled as

IN

.

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.

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.

4 - 60 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007

REV B

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.

Section 4 • Repair Procedures

MANIFOLDS

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 61

Section 4 • Repair Procedures June 2007

MANIFOLDS REV B

9-5

Generator Manifold Components

The generator manifold is located above the function manifold.

2

3

Index

No.

1

Description

Schematic

Item Function Torque

Solenoid valve, 2 position 3 way ......... DA .......... Generator on/off .................................. 25 ft-lbs / 34 Nm

Flow regulator, 4.3 gpm / 16.3 L/min ... DB .......... Generator speed ................................. 20 ft-lbs / 27.1 Nm

Relief valve, 3000 psi / 206.8 bar ........ DC .......... Generator circuit .................................. 20 ft-lbs / 27.1 Nm

1

Y29

DA

Note: 'alphanumeric' callouts refer to corresponding notes on the electrical schematic

DB

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic

2

3

DC

4 - 62 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B MANIFOLDS

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/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

1 Disconnect all electrical tools from the machine.

2 Start the engine from the platform controls.

3 Press the generator select switch.

Result: The generator should activate and the engine should go to high rpm.

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.

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 DB) 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.

9 Repeat steps 2 through 5 to confirm the generator AC voltage.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 63

Section 4 • Repair Procedures June 2007

MANIFOLDS REV B

9-7

Valve Coils

How to Test a Coil

A properly functioning coil provides an electromagnetic force which operates the solenoid valve. Critical to normal operation is continuity within the coil. Zero resistance or infinite resistance indicates the coil has failed.

Since coil resistance is sensitive to temperature, resistance values outside specification can produce erratic operation. When coil resistance decreases below specification, amperage increases. As resistance rises above specification, voltage increases.

While valves may operate when coil resistance is outside specification, maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

Note: If the machine has been in operation, allow the coil to cool at least 3 hours before performing this test.

1 Tag and disconnect the wiring from the coil to be tested.

2 Test the coil resistance using a multimeter set to resistance (

Ω)

. Refer to the Valve Coil

Resistance Specification table.

Result: If the resistance is not within the adjusted specification, plus or minus 10%, replace the coil.

Valve Coil Resistance

Specification

Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air temperature, the coil resistance will typically increase or decrease by 4% for each 18°F / 20°C that your air temperature increases or decreases from 68°F / 20°C.

Description

Solenoid valve, 2 position 2 way

12V DC with diode (schematic item AI)

Specification

9 Ω

Solenoid valve, 2 position 2 way

12V DC (schematic item BB)

7.5

Ω

Solenoid valve, 3 position 4 way

12V DC (schematic item BD)

7.5

Ω

Solenoid valve, 2 position 2 way

10V DC (schematic items CA, CB, CC and CD)

8.2

Ω

Solenoid valve, 2 position 3 way

12V DC (schematic item DA)

6 Ω

Solenoid valve, 2 position 2 way

12V DC with diode (schematic items FB and FK)

8.8

Ω

Solenoid valve, 2 position 4 way

12V DC with diode (schematic items FD, FQ and FT)

5 Ω

Solenoid valve, 3 position 4 way

12V DC with diode (schematic items FE and FR)

5

Ω

Solenoid valve, 3 position 4 way

12V DC with diode (schematic item FF)

8.8

Ω

Solenoid valve, 2 position 3 way

12V DC with diode (schematic item FP)

8.8

Ω

Proportional valve,

12V DC (schematic item FU)

5 Ω

4 - 64 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV B MANIFOLDS

How to Test a Coil Diode

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.

Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

1 Test the coil for resistance. See 9-3, How to

Test a Coil.

2 Connect a 10

:

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.

Note: The battery should read 9V DC or more when measured across the terminals.

Resistor, 10

:

Genie part number 27287

3 Set a multimeter to read DC current.

Note: The multimeter, when set to read DC current, should be capable of reading up to 800 mA.

COIL a d

MULTI

METER c

b

10 W

RESISTOR

9V

BATTERY c b

a multimeter b 9V DC battery c 10

:

resistor d 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.

Note: If testing a single-terminal coil, connect the negative lead to the internal metallic ring at either end of the coil.

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.

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. 112657 GS-2668 RT • GS-3268 RT 4 - 65

Section 4 • Repair Procedures

Fuel and Hydraulic Tanks

June 2007

REV A

10-1

Fuel Tank

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.

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.

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.

Note: 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 Tag, disconnect and plug the fuel supply and return hoses from the fuel tank.

5 Clean up any fuel that may have spilled.

6 Remove the fuel tank mounting fasteners.

7 Remove the fuel tank from the machine.

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.

Note: Clean the fuel tank and inspect for cracks or other damage before installing.

4 - 66 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV A FUEL AND HYDRAULIC TANKS

10-2

Hydraulic Tank

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.

Note: 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 2, Hydraulic Hose and

Fitting Torque Specifications.

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.

5 Close the two hydraulic shutoff valves located at the 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.

open closed

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.

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. 112657 GS-2668 RT • GS-3268 RT 4 - 67

Section 4 • Repair Procedures

Steer Axle Components

June 2007

REV A

11-1

Yoke and Drive Motor

How to Remove the Yoke and Drive Motor

Note: 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 2, Hydraulic Hose and

Fitting Torque Specifications.

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.

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 Support and secure the yoke and drive motor assembly to a lifting jack.

7 Remove the cotter pin from the tie rod clevis pin.

Note: Always use a new cotter pin when installing a clevis pin.

8 Remove the retaining fastener from the lower yoke pivot pin.

9 Place a rod through the pin and twist to remove the pin.

10 Repeat steps 7 through 9 for the upper yoke pivot pin.

11 Remove the yoke and drive motor assembly from the machine.

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.

4 - 68 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 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.

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.

Note: 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 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.

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. 112657 GS-2668 RT • GS-3268 RT 4 - 69

Section 4 • Repair Procedures June 2007

STEER AXLE COMPONENTS REV A

11-2

Steer Cylinder

How to Remove the

Steer Cylinder

Note: 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 2, 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.

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.

11-3

Tie Rod

How to Remove the Tie Rod

1 Remove the cotter pin from each tie rod clevis pin. Remove the clevis pins.

Note: Always use a new cotter pin when installing a clevis pin.

2 Remove the tie rod.

4 - 70 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

Non-steer Axle Components

REV A

12-1

Drive Motor and Brake

How to Remove a Drive Motor and Brake

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.

Note: 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 2, Hydraulic Hose and

Fitting Torque Specifications

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.

4 Remove the wheel lug bolts. Remove the tire and wheel assembly.

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.

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.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 71

Section 4 • Repair Procedures

Outrigger Components

June 2007

REV A

13-1

Outrigger Cylinder

How to Remove an Outrigger

Cylinder (if equipped)

Note: 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 2, Hydraulic Hose and

Fitting Torque Specifications

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.

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.

7 Remove the outrigger mounting fasteners. Slide the outrigger cylinder away from the machine.

Crushing hazard. The outrigger cylinder may become unbalanced and fall if not properly supported when removed from the machine.

Note: 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.

4 - 72 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV A

Brake Release Hand Pump Components

14-1

Brake Release Hand Pump Components

The brake release hand pump manifold is mounted at the non-steer end of the chassis on the ground controls side of the machine.

1

2

Index

No.

Description

Schematic

Item Function Torque

Hand pump ....................................... AG ............ Manual brake release .............................. 30 ft-lbs / 41 Nm

Needle valve ..................................... AH ............ Manual brake release enable .............. 45-50 in-lbs / 5 Nm

AG

3

4

AH

Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 73

Section 4 • Repair Procedures

Platform Overload Components

June 2007

REV A

15-1

Platform Overload System

How to Calibrate the Platform

Overload System (if equipped)

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.

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.

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.

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

GS-3268

975 kg

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 Loosen the retaining ring and remove the switch adjustment cover from the pressure switch.

Note: The pressure switch is located on the lower lift cylinder.

12 Using a small slotted screwdriver, turn the adjustment screw of the platform overload pressure switch one-quarter turn into the hydraulic line.

13 Push in the red Emergency Stop button to the off position at the ground controls.

4 - 74 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV A PLATFORM OVERLOAD COMPONENTS

14 Pull out the red Emergency Stop button to the on position at the ground controls. Wait 3 seconds and start the engine.

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.

Note: The red Emergency Stop button must be cycled after each quarter turn of the nut to allow the platform overload system to reset.

Note: Wait a minimum of 3 seconds between each quarter turn of the nut to allow the platform overload system to reset.

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.

Note: To perform this step, the lift relief valve will need to be adjusted.

Note: 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.

Result: The engine continues to run. Proceed to step 16.

Result: The engine has stopped and an alarm is sounding. Proceed to step 17.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 75

Section 4 • Repair Procedures June 2007

PLATFORM OVERLOAD COMPONENTS REV A

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.

Note: 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.

18 Push in the red Emergency Stop button to the off position at the ground controls.

19 Pull out the red Emergency Stop button to the on position at the ground controls. Wait 3 seconds and start the engine.

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.

Note: The red Emergency Stop button must be cycled after each quarter turn of the nut to allow the platform overload system to reset.

Note: Wait a minimum of 3 seconds between each quarter turn of the nut to allow the platform overload system to reset.

20 Return the safety arm to the stowed position.

Lower the platform to the stowed position.

Note: 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

GS-3268 RT

567 kg

454 kg

22 Raise the platform to approximately 4 m.

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.

4 - 76 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV A PLATFORM OVERLOAD COMPONENTS

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

GS-2668

GS-3268

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.

33 Turn the key switch to ground control.

Limit switch legend a maximum height limit switch b down limit switch c load sense delay limit switch

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 77

Section 4 • Repair Procedures June 2007

PLATFORM OVERLOAD COMPONENTS REV A

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 b c d a diagnostic display b blue platform up button c lift function enable button d yellow platform down button

35 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.

36 Press the lift function enable button.

Result:

DESCENT DELAY ON

is showing in the diagnostic display window.

37 Press the lift function enable button to deactivate the descent delay option.

Result:

DESCENT DELAY OFF

is showing in the diagnostic display window.

38 Push in the red Emergency Stop button to the off position at the ground controls.

39 Pull out the red Emergency Stop button to the on position at the ground controls.

Note: For more information on programming, refer to Section 4, Repair.

Calibrate the load sense delay limit switch:

40 Turn the key switch to platform control. Start the engine.

41 Lower the platform until the load sense delay limit switch activates and the platform stops lowering. Release the joystick.

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.

46 Return the safety arm to the stowed position.

47 Raise the platform approximately 1 m.

48 Repeat this procedure beginning with step 41.

4 - 78 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 4 • Repair Procedures

REV A PLATFORM OVERLOAD COMPONENTS

Enable the descent delay function:

49 Push in the red Emergency Stop button to the off position at the ground controls.

50 Turn the key switch to ground control.

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.

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.

53 Press the lift function enable button.

Result:

DESCENT DELAY OFF

is showing in the diagnostic display window.

54 Press the lift function enable button to activate the descent delay option.

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.

Calibrate the down limit switch:

57 Turn the key switch to platform control. Start the engine.

58 Raise the platform approximately 1 m.

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: 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.

61 Rotate the safety arm away from the machine and let it hang down.

62 Loosen the fasteners securing the down limit switch just enough to allow movement of the limit switch.

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.

Part No. 112657 GS-2668 RT • GS-3268 RT 4 - 79

Section 4 • Repair Procedures June 2007

PLATFORM OVERLOAD COMPONENTS REV A

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.

71 Move the roller head of the down limit switch

1 mm downwards. Tighten the fasteners. Do not over tighten.

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 or 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. See 9-2, How to

Adjust the Lift Relief Valve.

TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM

CANNOT LIFT RATED LOAD RELIEF VALVE SET TOO LOW

SOLUTION

INCREASE RELIEF VALVE PRESSURE

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

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

AT DOWN LIMIT WITH RATED LOAD IN

PLATFORM, THE PRESSURE SWITCH

ALARM CONTINUES TO SOUND

SYSTEM NEEDS TO BE RESET

TURN OFF RED EMERGENCY STOP

BUTTON, WAIT THREE SECONDS AND TURN

BACK ON

DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCH

TOO MUCH WEIGHT IN PLATFORM PUT CORRECT RATED LOAD IN PLATFORM

TURN THE PRESSURE SWITCH NUT 1/4

OVERLOAD SYSTEM NOT ADJUSTED

PROPERLY

TURN INTO THE HYDRAULIC LINE -OR-

REPEAT CALIBRATION PROCEDURE

4 - 80 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 5 • Fault Codes

Fault Codes

Observe and Obey:

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.

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

· Wheels chocked

· All external AC power supply disconnected from 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.

Be aware of the following hazards and follow generally accepted safe workshop practices.

Crushing hazard. When testing or replacing any hydraulic component, always support the structure and secure it from movement.

Electrocution/burn 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.

Part No. 112657 GS-2668 RT • GS-3268 RT 5 - 1

Section 5 • Fault Codes June 2007

FAULT CODES

About This Section

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

Malfunction discovered

Identify symptoms problem still exists

Return to service problem solved

Inspect and test

Troubleshoot

Perform repair

LED Diagnostic Readout

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.

5 - 2 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 5 • Fault Codes

REV B

Fault Code Chart

(from serial number GS6805-44771)

Fault Code LED Condition

SYSTEM READY Green Normal

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

DOWN SW FAULT

25

LEFT TURN SW

FAULT

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

31

PLATFORM

CHOKE SW

FAULT

32

PLATFORM

START SW FAULT

33

LEFT FRONT

OUTRIG SW FLT

Red

Red

Red

Red

Red

Red

Red

Internal ECM error.

Platform/ECM communication error.

Engine start button fault at ground controls.

Starting aid button fault at ground controls.

Up switch fault at ground controls.

Platform up/down enable button fault at ground controls.

Down switch fault at ground controls.

Red Left turn switch fault.

Red Right turn switch fault.

Red

Red

Red

Red

Red

Red

Red

Function enable switch on joystick is activated when machine is turned on.

Drive joystick off neutral when machine is turned on.

Lift enable button fault at the platform controls.

Up/down switch off neutral.

Starting aid fault at the platform controls.

Engine start button fault at platform controls.

Left front outrigger enable button fault at platform controls.

Result

System shutdown.

System shutdown.

Engine will not start.

Starting aid disabled.

Platform up function inoperable.

Platform up/down functions disabled.

Platform down function disabled.

Malfunctioning steer left microswitch.

Malfunctioning steer right microswitch.

Machine functions disabled.

Machine functions disabled.

Lift function disabled.

Up/down function disabled.

Starting aid disabled.

Engine will not start.

Outriggers disabled.

Replace ECM.

Solution

Troubleshoot control cable OR troubleshoot platform controls.

Replace ECM.

Replace ECM.

Replace ECM.

Replace ECM.

Replace ECM.

Troubleshoot steer left microswitch.

Troubleshoot steer right microswitch.

Release function enable switch on joystick before power up OR replace joystick.

Release joystick before power up OR replace joystick.

Troubleshoot button OR replace printed circuit board at platform controls.

Replace up/down switch at platform controls.

Troubleshoot button OR replace printed circuit board at platform controls.

Troubleshoot button OR replace printed circuit board at platform controls.

Troubleshoot button OR replace printed circuit board at platform controls.

Part No. 112657 GS-2668 RT • GS-3268 RT 5 - 3

Section 5 • Fault Codes June 2007

FAULT CODE CHART

(FROM SERIAL NUMBER GS6805-44771)

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

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

LED

Red

Red

Red

Red

Condition

Right front outrigger enable button fault at platform controls.

Left rear outrigger enable button fault at platform controls.

Right rear outrigger enable button fault at platform controls.

Outrigger autolevel enable button fault at platform controls.

Red

Red

Red

Red

Red

Red

Red

Red

Red

Red

Red

Red

Red

Drive coil 1 (Y1) fault.

Drive coil 2 (Y1A) fault.

Drive coil 3 (Y1B) fault.

Proportional coil (Y9) fault.

Up coil (Y8) fault.

Down coil (Y7) fault.

Right turn coil (Y3) fault.

Left turn coil (Y4) fault.

Brake release coil (Y2) fault.

Forward 1 coil (Y6) fault.

Reverse 1 coil (Y5) fault.

Forward 2 coil (Y6A) fault.

Reverse 2 coil (Y5A) fault.

Result

Outriggers disabled.

Outriggers disabled.

Outriggers disabled.

Outriggers disabled.

High speed drive function will not operate.

High speed drive function will not operate.

High speed drive function will not operate.

Lift and outrigger functions are disabled.

Platform will not raise.

Platform will not lower.

Machine will not turn right.

Machine will not turn left.

Brakes will not release.

Drives slow or not at all when elevated.

Drives slow or not at all when elevated.

Drives slow or not at all when elevated.

Drives slow or not at all when elevated.

REV B

Solution

Troubleshoot button OR replace printed circuit board at platform controls.

Troubleshoot button OR replace printed circuit board at platform controls.

Troubleshoot button OR replace printed circuit board at platform controls.

Troubleshoot button OR replace printed circuit board at platform controls.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

5 - 4 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 5 • Fault Codes

REV B FAULT CODE CHART

(FROM SERIAL NUMBER GS6805-44771)

Fault Code

66

LOW OIL

PRESSURE

67

HIGH COOLANT

TEMPERATURE

LED Condition

Red Low oil pressure. Engine stops.

Result

High engine temperature OR defective engine coolant or oil temperature switch.

Red

Right rear outrigger coil (Y34) fault.

Right rear outrigger disabled.

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.

Charge battery.

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

Red Low ECM voltage.

Red Low RPM.

Red High RPM.

Red

Left front outrigger coil (Y35) fault.

Red

Left rear outrigger coil (Y33) fault.

Red

Right front outrigger coil (Y36) fault.

Right front outrigger disabled.

Red

Outrigger extend coil (Y40) fault.

Red

Outrigger retract coil (Y39) fault.

Red

Outrigger slowdown coil (Y44) fault.

Outrigger slow extend function disabled.

Red 2 speed coil (Y1) fault

Red

Drive pump forward proportional coil (Y51) fault

Red

Drive pump reverse proportional coil (Y51) fault

System shutdown.

Engine idle RPM too low.

Engine RPM too high.

Left front outrigger disabled.

Left rear outrigger disabled.

Consult Genie Industries Service

Department.

Consult Genie Industries Service

Department.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Outrigger extend function disabled.

Troubleshoot coil OR wiring.

Outrigger retract function disabled.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

High torque drive function disabled. Troubleshoot coil OR wiring.

Drive forward function disabled.

Drive reverse function disabled.

Red Wrong machine type selected Machine will not operate.

Troubleshoot coil OR wiring.

Troubleshoot coil OR wiring.

Correct selection.

Part No. 112657 GS-2668 RT • GS-3268 RT 5 - 5

Section 5 • Fault Codes June 2007

This page intentionally left blank.

5 - 6 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 6 • Schematics

Schematics

Observe and Obey:

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.

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.

About This Section

There are two groups of schematics in this section.

An illustration legend precedes each group of drawings.

Electrical Schematics

Electrocution/burn hazard.

Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry.

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.

General Repair Process

Malfunction discovered

Identify symptoms

Troubleshoot problem still exists

Return to service problem solved

Inspect and test

Perform repair

Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 1

Section 6 • Schematics

Electronic Control Module Layout

(from serial number GS6805-44771)

June 2007

REV A

Platform controls

Engine

To outriggers

Flashing beacons

Down limit switch

Electronic Control Module

J1 J2

Generator

Outriggers and manifold

Level sensor

Horn

00009.9

Function manifold

GS-2668 RT • GS-3268 RT

STOP

Ground controls and ECM

Part No. 112657 6 - 2

June 2007

REV A

J1 Connector

(36 pin)

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

Right turn - Y3 (output)

Left turn - Y4 (output)

Platform up - Y8 (output)

Brake - Y2 (output)

Drive forward 1 - Y6 (output)

Drive reverse 2 - Y5A

Platform down - Y7

(output)

(output)

(GS-68)

Drive reverse 1 - Y5 (output)

Drive forward 2 - Y6A (output)

(GS-68)

(GS-68)

(GS-68)

Drive coil - Y1 (output)

Drive coil - Y1A (output)

Drive coil - Y1B (output)

B1

B2

B3

B3

B4

B5

B6

B7

B8

B9

B10

B11

B12

Generator - Y29

Drive reverse

(output)

- Y51 (output)

Proportional flow control - Y9

(GS-84/90)

(output) (GS-68)

Drive forward - Y51 (output) (GS-84/90)

Proportional flow control - Y9 (output) (GS-84/90)

Right front outrigger - Y36

Outrigger extend - Y40

(output)

(output)

Outrigger retract - Y39 (output)

Outrigger extend slow - Y44 (output) (GS-68)

Left front outrigger - Y35 (output)

Left rear outrigger - Y33 (output)

Right rear outrigger - Y34 (output)

LPG select/diesel shutoff (output)

C1

C2

C3

C4

C5

C6

C7

C8

C9

C10

C11

C12

Plug

Platform overload (input)

Right front outrigger limit switch LS13 (input)

Right rear outrigger limit switch LS12 (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

Section 6 • Schematics

Electronic Control Module Pin-Out Legend

(from serial number GS6805-44771)

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

A12

J2 Connector

(36 pin)

Up limit switch LS5 (input)

Down limit switchLS6 (input)

Aux down power (input)

Aux down relay CR23-86 (output)

Key switch KS1-3 (input)

Level sensor S7 (white) (input)

Plug

Plug

Plug

Platform controls (ground) (input)

Platform controls data high (+) (input)

Platform controls data low (-) (input)

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

B12

Level sensor S8 (blue) (input)

Level sensor S8 (black) (input)

Level sensor S8 (yellow) (input)

Plug

Plug

Plug

Engine start relay CR1-86 (output)

Ignition relay CR8-86 (output)

Engine high idle (output)

Level sensor S8 (red) (output)

Horn relay CR5-86 (output)

Alarm (output)

C7

C8

C9

C10

C11

C12

C1

C2

C3

C4

C5

C6

System power (input)

System power (input)

System power (input)

Engine starting aid (output)

Oscillate stowed relay CR84-86 (output)

Oscillate raised relay CR85-86 (output)

Ground (output)

Plug

Plug

Aux down relay CR23-87 (output)

Flashing beacons FS1 (output)

ECM power (input)

(GS-84/90)

C 1

B 1

A 1

6

6

6

36 pin connector

12

12

12

Part No. 112657

J1

Electronic Control Module

GS-2668 RT • GS-3268 RT

J2

6 - 3

Section 6 • Schematics

Wiring Diagram - Platform Control Box

(from serial number GS6805-44771)

COIL CORD ASSEMBLY

H1

ALARM

JC1

JOYSTICK

CONTROLLER

GY

BL

OR

RD

WH

BN

TS20

OR

TS21

BK

PP

YL

1

BK

NC 1

2

RD

OR

BL

WH

BK

RD

4

J3

1

GY

J5

5

1

U3

PLATFORM

CONTROLS

CIRCUIT

BOARD

P2

EMERGENCY

STOP

WH/BL

14

J2

6

1

J1

BK

YL

BL

RD

TS20

PLATFORM UP/DOWN TOGGLE SWITCH (MODELS WITHOUT OUTRIGGERS)

TS21

PLATFORM UP/DOWN / OUTRIGGER UP/DOWN TOGGLE SWITCH (MODELS WITH OUTRIGGERS)

June 2007

REV A

6 - 4 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 6 • Schematics

This page intentionally left blank.

Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 5

Section 6 • Schematics

Electrical Schematics Abbreviation and Wire Color Legends

June 2007

REV B

ELECTRICAL SCHEMATIC LEGEND

Item Description

B Battery

BN

C5

CB

CR

D

EN1

FB1

B1 = Engine start

B4 = Auxiliary platform down

Button

BN1 = Engine stop

BN2 = Engine start

BN3 = Glow plug

BN4 = High idle

BN5 = Horn

BN6 = High torque

BN7 = Generator

BN11 = Driving lights

BN12 = High speed lift enable

BN13 = Low speed lift enable

BN15 = Horn/left front outrigger

BN16 = Outrigger function enable

BN17 = High torque/left front outrigger

BN18 = Generator/right front outrigger

BN20 = Outrigger auto level

BN22 = Right rear outrigger

BN23 = Auxiliary platform down

Capacitor, 4700 uf

Circuit breaker

CB1 = 20 amp

CB2 = 1 amp (before serial number 24000)

CB2 = 7 amp (after serial number 23999)

Control relay

CR1 = Engine start

CR4 = High idle

CR5 = Horn relay

CR8 = Ignition

CR15 = Glow plug

CR17 = Hydraulic oil cooling fan

CR25 = Engine run

CR34 = Driving lights

CR43 = Power to ECM

Power supply

D1 = Alternator

D2 = Generator (option)

D7 = Voltage regulator — 12V DC to 5V DC

Platform control box enclosure

Flashing beacons (option)

G Gauge

G6 = Hour meter

G8 = Diagnostic display

GND Ground

H

JC4

Horn or alarm

H1 = Alarm, level sensor

H2 = Automotive-style horn

Joystick controller- drive, steer, platform up/down

L

LS

M

LED or light

L18 = Emergency stop

L19 = Power

L21 = High torque selected

L23 = High idle selected

L25 = Fault

L27 = Generator selected

L29 = Driving lights

L41 = Coolant temperature

L42 = Oil pressure

Limit switch

LS1 = Extension deck

LS5 = Platform up

LS6 = Platform down

LS12 = Left front outrigger

LS13 = Right front outrigger

LS14 = Left rear outrigger

LS15 = Right rear outrigger

Motor or pump

M1 = Hydraulic oil cooling fan

M3 = Engine starter

ELECTRICAL SCHEMATIC LEGEND

Item Description

*N Note

P

PS2

Q

QD

R

S

SW

TS

U

Y

Power

P1 = Emergency stop button at ground controls

P2 = Emergency stop button at platform controls

Platform overload pressure switch

Electro-mechanical solenoid

Q1 = LPG lockout

Q2 = Gasoline lockout

Q3 = High idle

Q8 = Fuel shut off

Quick disconnect

QD3 = Control cable to ground

QD4 = Control cable to platform

Resistor

R7 = 2000

:

resistor

R15 = 0 to 5000 ohm potentiometer

Sensor

S7 = Tilt sensor (models without outriggers)

S8 = Tilt sensor (models with outriggers)

Switch

SW1 = Engine coolant temperature

SW2 = Engine oil pressure

SW5 = Function enable

SW6 = Steer left/right

SW25 = DIP switch

Toggle switch

TS6 = Glow plug

TS20 = Platform up/down

TS21 = Platform up/down & outrigger extend/retract

TS52 = Engine start

TS53 = Fuel select

TS54 = Engine high idle

TS55 = Function enable

TS56 = Glow plug

TS66 = Platform up/down

TS67 = Function enable

Electronic component

U3 = Printed circuit board

U5 = Electronic control module

U19 = Ignition coil

U20 = Spark plug(s)

U26 = Distributor

U32 = Glow plug

Valve coil

Y1 = Drive parallel

Y1A = Drive parallel

Y1B = Drive parallel

Y2 = Brake release

Y3 = Steer right

Y4 = Steer left

Y5 = Drive reverse

Y5A = Drive reverse

Y6 = Drive forward

Y6A = Drive forward

Y7 = Platform down

Y7A = Platform down (GS-3268 only)

Y8 = Platform up

Y9 = Proportional flow control

Y10 = Auxiliary platform down(GS-3268 only

before serial number 40207)

Y10A = Auxiliary platform down (GS-3268 only)

Y29 = Generator on (option)

Y33 = Left rear outrigger

Y34 = Right rear outrigger

Y35 = Left front outrigger

Y36 = Right front outrigger

Y39 = Outrigger retract

Y40 = Outrigger extend

Y44 = Outrigger extend slow

WIRE COLOR

LEGEND

Item Description

BL Blue

BK Black

BR Brown

GN Green

OR Orange

PP Purple

RD Red

WH White

YL Yellow

BL/RD Blue/Red

BL/WH Blue/White

BK/RD Black/Red

OR/WH Orange/White

RD/BK Red/Black

RD/WH Red/White

WH/BL White/Blue

WH/BK White/Black

WH/RD White/Red

WH/YL White/Yellow

YL/BK Yellow/Black

6 - 6 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 6 • Schematics

Electrical Symbols Legend

REV A

P1

Emergency Stop button

KS1

PLATFORM

GROUND

GROUND

Key switch

Wire connection

30 86

87 85

Control relay

Solenoid valve with spike supression diode

M4

Motor or pump

Flashing beacon

Solenoid valve no diode

Spark plugs

Horn or alarm

No connection

(circuits crossing)

Button

Solenoid valve with redundant coils

Glow plug(s)

B

D

A

C

E

B

D

A

C

E

Quick disconnect

Diode

CB1

20A

Circuit breaker

M3

Pressure switch

Temperature switch

Electro-mechanical solenoid

D1

R

F

Alternator

Starter motor

S32

S33

S34

S35

S36

S37

S38

S39

DIP switch

LED

Toggle switch

Voltage regulator

(+)

Capacitor

) (

(+)

Ignition coil

G6 G6

Hour meter

Potentiometer

) (

12V DC

Battery

Limit switch

Resistor

Part No. 112657

Work lights

Distributor

GS-2668 RT • GS-3268 RT

Level sensor

(models without outriggers)

6 - 7

Section 6 • Schematics

Electrical Schematic

ANSI Models with Gasoline/LPG Power

(from serial number GS6805-44771)

Part 1 of 3

F9

5A FUSE

P1

EMERGENCY STOP

KS1 KEY SWITCH

2

B1

PLATFORM

CONTROL

4

B

3

GROUND

CONTROL

CB2

20A

June 2007

REV C

AB4 AB3

AB1

CR41

CONTROL

SYSTEM

(ESTOP 1)

86 30 1

85 87 87A

CR42

POWER

(ESTOP 2)

CR5

HORN

86 30 2

85 87 87A

86 30 5

85 87 87A

CR8

IGNITION

CR1

ENGINE

START

86 30 4

85 87 87A

86 30 3

85 87 87A

CR23

AUXILIARY

DOWN

G6

HOUR

METER

86 30 6

85 87 87A

N.C.

LS6

PLAT

DOWN

LIMIT

SWITCH

AB21

B1

+

STARTER

M3

-

H2

U19

(+)

) (

U26

BAT

EXCT D1 STA

86

CR15

STARTING

AID

30 7

85 87 87A

Q7

CHOKE

SOLENOID

L30

WORK LIGHTS

CR4

HIGH IDLE

86 30 8

85 87 87A

CB8

15A

U5

ECM

J1-C7

J2-C4

J2-B9

Q3

HIGH IDLE

SOLENOID

Y8

AB12

BN23

AUXILIARY DOWN

BN91

AUXILIARY DOWN

ENABLE

Y7A

Y7 Y10

Y10A

NOTE: CB8 ADDED AFTER

SERIAL NUMBER GS6806-45220

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 8 GS-2668 RT • GS-3268 RT

ES7161F

Part No. 112657

June 2007

REV C

Section 6 • Schematics

Electrical Schematic

ANSI Models with Gasoline/LPG Power

(from serial number GS6805-44771)

Part 2 of 3

CR8 TERMINAL 30

BATTERY (+)

F9A

20A

CR17 30 86

87 85

AB2

SW4

N.O.

HYDRAULIC

OIL COOLER

(OPTION)

M1

BATTERY (-)

LEVEL SENSOR

CIRCUIT BOARD

N.C.

S7 LEVEL

SENSOR

MODELS WITHOUT

OUTRIGGERS

BK

AB1

AB29

AB23

U5

ELECTRONIC CONTROL MODULE

AB22 AB11

SW2 SW1 H5 FB1

Y4 Y1 Y1A Y2 Y6 Y6A

AB13

Q1 Q2

Y3 Y1.1

Y1B Y5 Y5A Y9 Y29

M4

ES7161F

Part No. 112657 GS-2668 RT • GS-3268 RT

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 9

Section 6 • Schematics

Electrical Schematic

ANSI Models with Gasoline/LPG Power

(from serial number GS6805-44771)

Part 3 of 3

WH/RD

RD/WH

BL

BK

OR

QD4

4

2

5

3

1

4

3

1

2

5

AB3

OUTRIGGERS

(OPTION)

AB3 AB2 AB2

S8

2 AXIS

TILT LEVEL

SENSOR

LS12

LF

O-RIG

LIMIT

SWITCH

LS13

RF

O-RIG

LIMIT

SWITCH

LS14

LR

O-RIG

LIMIT

SWITCH

LS15

RR

O-RIG

LIMIT

SWITCH

N.O.

N.O.

N.O.

N.O.

AB27 AB26 AB17 AB16

AB23

AB25

AB24

AB1

6 - 10

AB9

Y36

AB10

AB15

Y34

AB14

AB8

Y40

AB7

AB6

Y44

Y35 Y33 Y39

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

June 2007

REV C

1

2

4

3

5

QD3

4

3

1

2

5

BK

RD

WH

BL

OR

POWER TO PLATFORM

POWER TO GROUND

GROUND

DATA LINK (HIGH)

DATA LINK (LOW)

BK

RD

WH

BL

OR

P2

EMERGENCY

J5 PIN1

J5 PIN4

J5 PIN5

STOP

U5

ELECTRONIC

CONTROL

MODULE

U3

PLATFORM CONTROLS

PRINTED CIRCUIT BOARD

J5 PIN2

D7

VOLTAGE

REGULATOR

12V DC

5V DC

PIN5

PIN6

PIN7

PIN8

PIN9

PIN10

PIN11

PIN12

PIN13

PIN14

PIN15

J2 PIN1

J2 PIN2

J2 PIN12

J2 PIN13

J2 PIN3

J2 PIN4

J5 PIN3

J2 PIN5

J2 PIN6

J2 PIN7

J2 PIN8

J2 PIN14

POUT1

PIN2

PIN3

PIN4

GY

YL

WH

BN

BL

PP

GY

OR

BK

RD

WH/BL

HALL EFFECT

GENERATOR

SW5

FUNCTION ENABLE

JC1

JOYSTICK

CONTROLLER

SW6

STEER

LEFT/ RIGHT

HORN BN5

STARTING AID BN3

ENGINE START BN2

HIGH TORQUE BN6

GENERATOR BN7

LPG SELECT BN14

HIGH IDLE BN4

LF OUTRIGGER ENABLE BN85

RF OUTRIGGER ENABLE BN86

LR OUTRIGGER ENABLE BN87

RR OUTRIGGER ENABLE BN24

LIFT FUNCTION BN9

ORGR AUTOLEVEL ENABLE BN20

SYSTEM STATUS L50

J1 PIN4

J1 PIN3

J1 PIN1

J1 PIN5

J3 PIN1

J3 PIN2

YL

BL

RD

BK

RD

BK

+

H1

ALARM

PLATFORM UP/DOWN TS20

-OR-

PLATFORM & OUTRIGGER

UP/DOWN

TS21

PLATFORM

CONTROLS

ES7161F

GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 6 • Schematics

This page intentionally left blank.

Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 11

Section 6 • Schematics

Electrical Schematic

CE Models with Gasoline/LPG Power

(from serial number GS6805-44771)

Part 1 of 3

F9

5A FUSE

P1

EMERGENCY STOP

KS1 KEY SWITCH

2

B1

PLATFORM

CONTROL

4

B

R25

5 OHM 3

GROUND

CONTROL

PS2A

PLATFORM OVERLOAD PRESSURE SWITCH

AB20

CB2

20A

AB4

AB28

AB1

June 2007

REV C

B1

+

-

CR41

CONTROL

SYSTEM

(ESTOP 1)

86 30 1

85 87 87A

CR42

POWER

(ESTOP 2)

86 30 2

85 87 87A

CR5

HORN

AB1

86 30 5

85 87 87A

CR8

IGNITION

CR1

ENGINE

START

86 30 4

85 87 87A

86 30 3

85 87 87A

STARTER

M3

H2

CR23

AUXILIARY

DOWN

G6

HOUR

METER

86 30 6

85 87 87A

N.C.

LS6

PLAT

DOWN

LIMIT

SWITCH

AB21

U5

ECM

U19

(+)

) (

U26

BAT

EXCT D1 STA

AB1

86

CR15

STARTING

AID

30 7

85 87 87A

86

CR4

HIGH IDLE

AB1

30 8

L30

WORK

LIGHTS

85 87 87A

CB8

15A

Q7

CHOKE

SOLENOID

Q3

HIGH IDLE

SOLENOID

J1-C7

J2-C4

BN23

AUXILIARY DOWN

J2-B9

LS24

MAXIMUM

HEIGHT

LIMIT SW

N.C.

AB12

LS25

LOAD SENSE

DELAY

LIMIT SW

86

CR77

DOWN

ENABLE

85

N.C.

30

87

9

87A

C5

4700 uF

Y7A

BN91

AUXILIARY DOWN

ENABLE

Y10A

Y8 Y7 Y10

NOTE: CB8 ADDED AFTER

SERIAL NUMBER GS6806-45220

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 12 GS-2668 RT • GS-3268 RT

ES7183G

Part No. 112657

June 2007

REV C

Section 6 • Schematics

Electrical Schematic

CE Models with Gasoline/LPG Power

(from serial number GS6805-44771)

Part 2 of 3

CR8 TERMINAL 30

BATTERY (+)

F9A

20A

CR17 30 86

87 85

AB2

SW4

N.O.

HYDRAULIC

OIL COOLER

(OPTION)

M1

BATTERY (-)

LEVEL SENSOR

CIRCUIT BOARD

N.C.

S7 LEVEL

SENSOR

MODELS WITHOUT

OUTRIGGERS

BK

AB1

AB29

AB23

U5

ELECTRONIC CONTROL MODULE

AB22 AB11

SW2 SW1 H5 FB1

Y4 Y1 Y1A Y2 Y6 Y6A

AB13

Q1 Q2

Y3 Y1.1

Y1B Y5 Y5A Y9 Y29

M4

ES7183G

Part No. 112657 GS-2668 RT • GS-3268 RT

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 13

Section 6 • Schematics

Electrical Schematic

CE Models with Gasoline/LPG Power

(from serial number GS6805-44771)

Part 3 of 3

WH/RD

RD/WH

BL

BK

OR

QD4

4

2

5

3

1

4

3

1

2

5

AB3

OUTRIGGERS

(OPTION)

AB3 AB2 AB2

S8

2 AXIS

TILT LEVEL

SENSOR

LS12

LF

O-RIG

LIMIT

SWITCH

LS13

RF

O-RIG

LIMIT

SWITCH

LS14

LR

O-RIG

LIMIT

SWITCH

LS15

RR

O-RIG

LIMIT

SWITCH

N.O.

N.O.

N.O.

N.O.

AB27 AB26 AB17 AB16

AB23

AB25

AB24

AB1

6 - 14

AB9

Y36

AB10

AB15

Y34

AB14

AB8

Y40

AB7

AB6

Y44

Y35 Y33 Y39

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

June 2007

REV C

1

2

4

3

5

QD3

4

3

1

2

5

BK

RD

WH

BL

OR

POWER TO PLATFORM

POWER TO GROUND

GROUND

DATA LINK (HIGH)

DATA LINK (LOW)

BK

RD

WH

BL

OR

P2

EMERGENCY

J5 PIN1

J5 PIN4

J5 PIN5

STOP

U5

ELECTRONIC

CONTROL

MODULE

U3

PLATFORM CONTROLS

PRINTED CIRCUIT BOARD

J5 PIN2

D7

VOLTAGE

REGULATOR

12V DC

5V DC

PIN5

PIN6

PIN7

PIN8

PIN9

PIN10

PIN11

PIN12

PIN13

PIN14

PIN15

J2 PIN1

J2 PIN2

J2 PIN12

J2 PIN13

J2 PIN3

J2 PIN4

J5 PIN3

J2 PIN5

J2 PIN6

J2 PIN7

J2 PIN8

J2 PIN14

POUT1

PIN2

PIN3

PIN4

GY

YL

WH

BN

BL

PP

GY

OR

BK

RD

WH/BL

HALL EFFECT

GENERATOR

SW5

FUNCTION ENABLE

JC1

JOYSTICK

CONTROLLER

SW6

STEER

LEFT/ RIGHT

HORN BN5

STARTING AID BN3

ENGINE START BN2

HIGH TORQUE BN6

GENERATOR BN7

LPG SELECT BN14

HIGH IDLE BN4

LF OUTRIGGER ENABLE BN85

RF OUTRIGGER ENABLE BN86

LR OUTRIGGER ENABLE BN87

RR OUTRIGGER ENABLE BN24

LIFT FUNCTION BN9

ORGR AUTOLEVEL ENABLE BN20

SYSTEM STATUS L50

J1 PIN4

J1 PIN3

J1 PIN1

J1 PIN5

J3 PIN1

J3 PIN2

YL

BL

RD

BK

RD

BK

+

H1

ALARM

PLATFORM UP/DOWN TS20

-OR-

PLATFORM & OUTRIGGER

UP/DOWN

TS21

PLATFORM

CONTROLS

ES7183G

GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 6 • Schematics

This page intentionally left blank.

Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 15

Section 6 • Schematics

Electrical Schematic

ANSI Models with Diesel Power

(from serial number GS6805-44771 to GS6806-45204)

Part 1 of 3

F9

5A FUSE

P1

EMERGENCY STOP

KS1 KEY SWITCH

2

B1

PLATFORM

CONTROL

4

B

3

GROUND

CONTROL

CB2

20A

AB3 AB7

June 2007

REV C

AB28

AB3 AB3

AB1

CR41

CONTROL

SYSTEM

(ESTOP 1)

86 30 1

85 87 87A

CR42

POWER

(ESTOP 2)

86 30 2

85 87 87A

CR5

HORN

AB1

86 30 5

85 87 87A

CR8

IGNITION

CR1

ENGINE

START

86 30 4

85 87 87A

86 30 3

85 87 87A

CR23

AUXILIARY

DOWN

G6

HOUR

METER

86 30 6

85 87 87A

N.C.

LS6

PLAT

DOWN

LIMIT

SWITCH

B1

+

-

U5

ECM

STARTER

M3

EXCT

BAT

D1 STA

F9

30A 86

CR15

STARTING

AID

30 7

85 87 87A

H2

Q8

FUEL

SHUT

OFF

U32

GLOW

PLUG

(OPTION)

CR4

HIGH IDLE

L30

WORK

LIGHTS

86 30 8

85 87 87A

Q3

HIGH IDLE

SOLENOID

C5

4700 uF

Y8

J1-C7

J2-C4

J2-B9

Y7

BN23

AUXILIARY DOWN

BN91

AUXILIARY DOWN

ENABLE

Y7A

Y10

Y10A

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 16 GS-2668 RT • GS-3268 RT

ES7162E

Part No. 112657

June 2007

REV C

Section 6 • Schematics

Electrical Schematic

ANSI Models with Diesel Power

(from serial number GS6805-44771 to GS6806-45204)

Part 2 of 3

CR8 TERMINAL 30

BATTERY (+)

F9A

20A

CR17 30 86

87 85

AB2

SW4

N.O.

HYDRAULIC

OIL COOLER

(OPTION)

M1

BATTERY (-)

LEVEL SENSOR

CIRCUIT BOARD

N.C.

S7 LEVEL

SENSOR

MODELS WITHOUT

OUTRIGGERS

BK

AB1

AB29

AB23

U5

ELECTRONIC CONTROL MODULE

AB22 AB11

Y4 Y1 Y1A Y2 Y5 Y5A

AB13

Y9

SW2 SW1 H5 FB1

Y3 Y1.1

Y1B Y6 Y6A Y29

ES7162E

Part No. 112657 GS-2668 RT • GS-3268 RT

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 17

Section 6 • Schematics June 2007

Electrical Schematic

ANSI Models with Diesel Power

(from serial number GS6805-44771 to GS6806-45204)

Part 3 of 3

WH/RD

RD/WH

BL

BK

OR

QD4

4

2

5

3

1

4

3

1

2

5

1

2

4

3

5

QD3

4

3

1

2

5

BK

RD

WH

BL

OR

POWER TO PLATFORM

POWER TO GROUND

GROUND

DATA LINK (HIGH)

DATA LINK (LOW)

BK

RD

WH

BL

OR

J5 PIN1

J5 PIN4

J5 PIN5

REV C

P2

EMERGENCY

STOP

AB3

OUTRIGGERS

(OPTION)

AB3 AB2 AB2

S8

2 AXIS

TILT LEVEL

SENSOR

LS12

LF

O-RIG

LIMIT

SWITCH

LS13

RF

O-RIG

LIMIT

SWITCH

LS14

LR

O-RIG

LIMIT

SWITCH

LS15

RR

O-RIG

LIMIT

SWITCH

N.O.

N.O.

N.O.

N.O.

AB27 AB26 AB17 AB16

AB23

AB25

AB24

AB1

AB9

Y36

AB10

AB15

Y34

AB14

AB8

Y40

AB7

AB6

Y44

Y35 Y33 Y39

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

U5

ELECTRONIC

CONTROL

MODULE

ES7162E

U3

PLATFORM CONTROLS

PRINTED CIRCUIT BOARD

J5 PIN2

D7

VOLTAGE

REGULATOR

12V DC

5V DC

PIN5

PIN6

PIN7

PIN8

PIN9

PIN10

PIN11

PIN12

PIN13

PIN14

PIN15

J2 PIN1

J2 PIN2

J2 PIN12

J2 PIN13

J2 PIN3

J2 PIN4

J5 PIN3

J2 PIN5

J2 PIN6

J2 PIN7

J2 PIN8

J2 PIN14

POUT1

PIN2

PIN3

PIN4

GY

YL

WH

BN

BL

PP

GY

OR

BK

RD

WH/BL

HALL EFFECT

GENERATOR

SW5

FUNCTION ENABLE

JC1

JOYSTICK

CONTROLLER

SW6

STEER

LEFT/ RIGHT

HORN BN5

STARTING AID BN3

ENGINE START BN2

HIGH TORQUE BN6

GENERATOR BN7

LPG SELECT BN14

HIGH IDLE BN4

LF OUTRIGGER ENABLE BN85

RF OUTRIGGER ENABLE BN86

LR OUTRIGGER ENABLE BN87

RR OUTRIGGER ENABLE BN24

LIFT FUNCTION BN9

ORGR AUTOLEVEL ENABLE BN20

SYSTEM STATUS L50

J1 PIN4

J1 PIN3

J1 PIN1

J1 PIN5

J3 PIN1

J3 PIN2

YL

BL

RD

BK

RD

BK

+

H1

ALARM

PLATFORM UP/DOWN TS20

-OR-

PLATFORM & OUTRIGGER

UP/DOWN

TS21

PLATFORM

CONTROLS

6 - 18 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 6 • Schematics

This page intentionally left blank.

Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 19

Section 6 • Schematics

Electrical Schematic

ANSI Models with Diesel Power

(from serial number GS6806-45205)

Part 1 of 3

F9

5A FUSE

P1

EMERGENCY STOP

KS1 KEY SWITCH

2

B1

PLATFORM

CONTROL

4

B

3

GROUND

CONTROL

CB2

20A

AB3 AB7 AB3 AB3

AB1

June 2007

REV C

CR41

CONTROL

SYSTEM

(ESTOP 1)

86 30 1

85 87 87A

CR42

POWER

(ESTOP 2)

86 30 2

85 87 87A

CR5

HORN

AB1

86 30 5

85 87 87A

CR8

IGNITION

CR1

ENGINE

START

86 30 4

85 87 87A

86 30 3

85 87 87A

CR23

AUXILIARY

DOWN

G6

HOUR

METER

86 30 6

85 87 87A

N.C.

LS6

PLAT

DOWN

LIMIT

SWITCH

B1

+

-

STARTER

M3

H2

U5

ECM

EXCT

BAT

D1 STA

F9

30A

Q8

FUEL

SHUT

OFF

86

CR15

STARTING

AID

30 7

85 87 87A

F9B

50A (D-905)

40A

(403C11)

86

CR4

HIGH IDLE

L30

WORK

LIGHTS

30 8

85 87 87A

CB8

15A

U32

GLOW

PLUG

(OPTION)

Q3

HIGH IDLE

SOLENOID

C5

4700 uF

Y8

J1-C7

J2-C4

J2-B9

Y7

BN23

AUXILIARY DOWN

BN91

AUXILIARY DOWN

ENABLE

Y7A

Y10

Y10A

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

NOTE: CB8 ADDED AFTER

SERIAL NUMBER GS6806-45220

NOTE: F9B ADDED AFTER

SERIAL NUMBER GS6806-47220

6 - 20 GS-2668 RT • GS-3268 RT

ES7162G

Part No. 112657

June 2007

REV C

Section 6 • Schematics

Electrical Schematic

ANSI Models with Diesel Power

(from serial number GS6806-45205)

Part 2 of 3

CR8 TERMINAL 30

BATTERY (+)

F9A

20A

CR17 30 86

87 85

AB2

SW4

N.O.

HYDRAULIC

OIL COOLER

(OPTION)

M1

BATTERY (-)

LEVEL SENSOR

CIRCUIT BOARD

N.C.

S7 LEVEL

SENSOR

MODELS WITHOUT

OUTRIGGERS

BK

AB1

AB29

AB23

U5

ELECTRONIC CONTROL MODULE

AB22 AB11

Y4 Y1 Y1A Y2 Y5 Y5A

AB13

Y9

SW2 SW1 H5 FB1

Y3 Y1.1

Y1B Y6 Y6A Y29

ES7162G

Part No. 112657 GS-2668 RT • GS-3268 RT

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 21

Section 6 • Schematics

Electrical Schematic

ANSI Models with Diesel Power

(from serial number GS6806-45205)

Part 3 of 3

WH/RD

RD/WH

BL

BK

OR

QD4

4

2

5

3

1

4

3

1

2

5

AB3

OUTRIGGERS

(OPTION)

AB3 AB2 AB2

S8

2 AXIS

TILT LEVEL

SENSOR

LS12

LF

O-RIG

LIMIT

SWITCH

LS13

RF

O-RIG

LIMIT

SWITCH

LS14

LR

O-RIG

LIMIT

SWITCH

LS15

RR

O-RIG

LIMIT

SWITCH

N.O.

N.O.

N.O.

N.O.

AB27 AB26 AB17 AB16

AB23

AB25

AB24

AB1

6 - 22

AB9

Y36

AB10

AB15

Y34

AB14

AB8

Y40

AB7

AB6

Y44

Y35 Y33 Y39

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

June 2007

REV C

1

2

4

3

5

QD3

4

3

1

2

5

BK

RD

WH

BL

OR

POWER TO PLATFORM

POWER TO GROUND

GROUND

DATA LINK (HIGH)

DATA LINK (LOW)

BK

RD

WH

BL

OR

P2

EMERGENCY

J5 PIN1

J5 PIN4

J5 PIN5

STOP

U5

ELECTRONIC

CONTROL

MODULE

U3

PLATFORM CONTROLS

PRINTED CIRCUIT BOARD

J5 PIN2

D7

VOLTAGE

REGULATOR

12V DC

5V DC

PIN5

PIN6

PIN7

PIN8

PIN9

PIN10

PIN11

PIN12

PIN13

PIN14

PIN15

J2 PIN1

J2 PIN2

J2 PIN12

J2 PIN13

J2 PIN3

J2 PIN4

J5 PIN3

J2 PIN5

J2 PIN6

J2 PIN7

J2 PIN8

J2 PIN14

POUT1

PIN2

PIN3

PIN4

GY

YL

WH

BN

BL

PP

GY

OR

BK

RD

WH/BL

HALL EFFECT

GENERATOR

SW5

FUNCTION ENABLE

JC1

JOYSTICK

CONTROLLER

SW6

STEER

LEFT/ RIGHT

HORN BN5

STARTING AID BN3

ENGINE START BN2

HIGH TORQUE BN6

GENERATOR BN7

LPG SELECT BN14

HIGH IDLE BN4

LF OUTRIGGER ENABLE BN85

RF OUTRIGGER ENABLE BN86

LR OUTRIGGER ENABLE BN87

RR OUTRIGGER ENABLE BN24

LIFT FUNCTION BN9

ORGR AUTOLEVEL ENABLE BN20

SYSTEM STATUS L50

J1 PIN4

J1 PIN3

J1 PIN1

J1 PIN5

J3 PIN1

J3 PIN2

YL

BL

RD

BK

RD

BK

+

H1

ALARM

PLATFORM UP/DOWN TS20

-OR-

PLATFORM & OUTRIGGER

UP/DOWN

TS21

PLATFORM

CONTROLS

ES7162G

GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 6 • Schematics

This page intentionally left blank.

Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 23

Section 6 • Schematics

Electrical Schematic

CE Models with Diesel Power

(from serial number GS6805-44771 to GS6806-45204)

Part 1 of 3

F9

5A FUSE

P1

EMERGENCY STOP

KS1 KEY SWITCH

2

B1

PLATFORM

CONTROL

PS2A

PLATFORM OVERLOAD PRESSURE SWITCH

4

B

R25

5 OHM

3

GROUND

CONTROL

AB20

CB2

20A

AB4

AB28

AB3

AB1

June 2007

REV C

CR41

CONTROL

SYSTEM

(ESTOP 1)

86 30 1

85 87 87A

CR42

POWER

(ESTOP 2)

86 30 2

85 87 87A

CR5

HORN

AB1

86 30 5

85 87 87A

CR8

IGNITION

CR1

ENGINE

START

86 30 4

85 87 87A

86 30 3

85 87 87A

CR23

AUXILIARY

DOWN

G6

HOUR

METER

86 30 6

85 87 87A

N.C.

LS6

PLAT

DOWN

LIMIT

SWITCH

B1

+

-

STARTER

M3

H2

U5

ECM

EXCT

BAT

D1 STA

F9

30A 86

CR15

STARTING

AID

30 7

85 87 87A

Q8

FUEL

SHUT

OFF

U32

GLOW

PLUG

(OPTION)

Q3

HIGH IDLE

SOLENOID

Y8

J1-C7

J2-C4

J2-B9

Y7

BN23

AUXILIARY DOWN

CR4

HIGH IDLE

L30

WORK

LIGHTS

86 30 8

85 87 87A

LS24

MAXIMUM

HEIGHT

LIMIT SW

N.C.

AB12

LS25

LOAD SENSE

DELAY

LIMIT SW

86

CR77

DOWN

ENABLE

85

N.C.

30

87

9

87A

C5

4700 uF

Y7A

Y10

BN91

AUXILIARY DOWN

ENABLE

Y10A

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 24 GS-2668 RT • GS-3268 RT

ES7184D

Part No. 112657

June 2007

REV C

Section 6 • Schematics

Electrical Schematic

CE Models with Diesel Power

(from serial number GS6805-44771 to GS6806-45204)

Part 2 of 3

CR8 TERMINAL 30

BATTERY (+)

F9A

20A

CR17 30 86

87 85

AB2

SW4

N.O.

HYDRAULIC

OIL COOLER

(OPTION)

M1

BATTERY (-)

LEVEL SENSOR

CIRCUIT BOARD

N.C.

S7 LEVEL

SENSOR

MODELS WITHOUT

OUTRIGGERS

BK

AB1

AB29

AB23

U5

ELECTRONIC CONTROL MODULE

AB22 AB11

Y4 Y1 Y1A Y2 Y5 Y5A

AB13

Y9

SW2 SW1 H5 FB1

Y3 Y1.1

Y1B Y6 Y6A Y29

ES7184D

Part No. 112657 GS-2668 RT • GS-3268 RT

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 25

Section 6 • Schematics June 2007

Electrical Schematic

CE Models with Diesel Power

(from serial number GS6805-44771 to GS6806-45204)

Part 3 of 3

WH/RD

RD/WH

BL

BK

OR

QD4

4

2

5

3

1

4

3

1

2

5

1

2

4

3

5

QD3

4

3

1

2

5

BK

RD

WH

BL

OR

POWER TO PLATFORM

POWER TO GROUND

GROUND

DATA LINK (HIGH)

DATA LINK (LOW)

BK

RD

WH

BL

OR

J5 PIN1

J5 PIN4

J5 PIN5

REV C

P2

EMERGENCY

STOP

AB3

OUTRIGGERS

(OPTION)

AB3 AB2 AB2

S8

2 AXIS

TILT LEVEL

SENSOR

LS12

LF

O-RIG

LIMIT

SWITCH

LS13

RF

O-RIG

LIMIT

SWITCH

LS14

LR

O-RIG

LIMIT

SWITCH

LS15

RR

O-RIG

LIMIT

SWITCH

N.O.

N.O.

N.O.

N.O.

AB27 AB26 AB17 AB16

AB23

AB25

AB24

AB1

AB9

Y36

AB10

AB15

Y34

AB14

AB8

Y40

AB7

AB6

Y44

Y35 Y33 Y39

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

U5

ELECTRONIC

CONTROL

MODULE

ES7184D

U3

PLATFORM CONTROLS

PRINTED CIRCUIT BOARD

J5 PIN2

D7

VOLTAGE

REGULATOR

12V DC

5V DC

PIN5

PIN6

PIN7

PIN8

PIN9

PIN10

PIN11

PIN12

PIN13

PIN14

PIN15

J2 PIN1

J2 PIN2

J2 PIN12

J2 PIN13

J2 PIN3

J2 PIN4

J5 PIN3

J2 PIN5

J2 PIN6

J2 PIN7

J2 PIN8

J2 PIN14

POUT1

PIN2

PIN3

PIN4

GY

YL

WH

BN

BL

PP

GY

OR

BK

RD

WH/BL

HALL EFFECT

GENERATOR

SW5

FUNCTION ENABLE

JC1

JOYSTICK

CONTROLLER

SW6

STEER

LEFT/ RIGHT

HORN BN5

STARTING AID BN3

ENGINE START BN2

HIGH TORQUE BN6

GENERATOR BN7

LPG SELECT BN14

HIGH IDLE BN4

LF OUTRIGGER ENABLE BN85

RF OUTRIGGER ENABLE BN86

LR OUTRIGGER ENABLE BN87

RR OUTRIGGER ENABLE BN24

LIFT FUNCTION BN9

ORGR AUTOLEVEL ENABLE BN20

SYSTEM STATUS L50

J1 PIN4

J1 PIN3

J1 PIN1

J1 PIN5

J3 PIN1

J3 PIN2

YL

BL

RD

BK

RD

BK

+

H1

ALARM

PLATFORM UP/DOWN TS20

-OR-

PLATFORM & OUTRIGGER

UP/DOWN

TS21

PLATFORM

CONTROLS

6 - 26 GS-2668 RT • GS-3268 RT Part No. 112657

June 2007 Section 6 • Schematics

This page intentionally left blank.

Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 27

Section 6 • Schematics

Electrical Schematic

CE Models with Diesel Power

(from serial number GS6806-45205)

Part 1 of 3

F9

5A FUSE

P1

EMERGENCY STOP

KS1 KEY SWITCH

2

B1

PLATFORM

CONTROL

4

B

R25

5 OHM

3

GROUND

CONTROL

PS2A

PLATFORM OVERLOAD PRESSURE SWITCH

AB20

CB2

20A

AB4

AB28

AB3

AB1

June 2007

REV C

CR41

CONTROL

SYSTEM

(ESTOP 1)

86 30 1

85 87 87A

CR42

POWER

(ESTOP 2)

86 30 2

85 87 87A

CR5

HORN

AB1

86 30 5

85 87 87A

CR8

IGNITION

CR1

ENGINE

START

86 30 4

85 87 87A

86 30 3

85 87 87A

CR23

AUXILIARY

DOWN

G6

HOUR

METER

86 30 6

85 87 87A

N.C.

LS6

PLAT

DOWN

LIMIT

SWITCH

B1

+

-

STARTER

M3

H2

U5

ECM

EXCT

F9

30A

Q8

FUEL

SHUT

OFF

BAT

D1 STA

J1-C7

J2-C4

J2-B9

BN23

AUXILIARY DOWN

BN91

AUXILIARY DOWN

ENABLE

86

CR15

STARTING

AID

30 7

85 87 87A

F9B

50A (D-905)

40A

(403C11)

U32

GLOW

PLUG

(OPTION)

86

CR4

HIGH IDLE

L30

WORK

LIGHTS

30 8

85 87 87A

CB8

15A

Q3

HIGH IDLE

SOLENOID

LS24

MAXIMUM

HEIGHT

LIMIT SW

N.C.

AB12

LS25

LOAD SENSE

DELAY

LIMIT SW

86

CR77

DOWN

ENABLE

85

N.C.

30

87

9

87A

C5

4700 uF

Y8 Y7

Y7A

Y10

Y10A

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

NOTE: CB8 ADDED AFTER

SERIAL NUMBER GS6806-45220

NOTE: F9B ADDED AFTER

SERIAL NUMBER GS6806-47220

6 - 28 GS-2668 RT • GS-3268 RT

ES7184G

Part No. 112657

June 2007

REV C

Section 6 • Schematics

Electrical Schematic

CE Models with Diesel Power

(from serial number GS6806-45205)

Part 2 of 3

CR8 TERMINAL 30

BATTERY (+)

F9A

20A

CR17 30 86

87 85

AB2

SW4

N.O.

HYDRAULIC

OIL COOLER

(OPTION)

M1

BATTERY (-)

LEVEL SENSOR

CIRCUIT BOARD

N.C.

S7 LEVEL

SENSOR

MODELS WITHOUT

OUTRIGGERS

BK

AB1

AB29

AB23

U5

ELECTRONIC CONTROL MODULE

AB22 AB11

Y4 Y1 Y1A Y2 Y5 Y5A

AB13

Y9

SW2 SW1 H5 FB1

Y3 Y1.1

Y1B Y6 Y6A Y29

ES7184G

Part No. 112657 GS-2668 RT • GS-3268 RT

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

6 - 29

Section 6 • Schematics

Electrical Schematic

CE Models with Diesel Power

(from serial number GS6806-45205)

Part 3 of 3

WH/RD

RD/WH

BL

BK

OR

QD4

4

2

5

3

1

4

3

1

2

5

AB3

OUTRIGGERS

(OPTION)

AB3 AB2 AB2

S8

2 AXIS

TILT LEVEL

SENSOR

LS12

LF

O-RIG

LIMIT

SWITCH

LS13

RF

O-RIG

LIMIT

SWITCH

LS14

LR

O-RIG

LIMIT

SWITCH

LS15

RR

O-RIG

LIMIT

SWITCH

N.O.

N.O.

N.O.

N.O.

AB27 AB26 AB17 AB16

AB23

AB25

AB24

AB1

6 - 30

AB9

Y36

AB10

AB15

Y34

AB14

AB8

Y40

AB7

AB6

Y44

Y35 Y33 Y39

- NOTE -

MACHINE SHOWN IN THE STOWED

POSITION WITH THE POWER OFF

June 2007

REV C

1

2

4

3

5

QD3

4

3

1

2

5

BK

RD

WH

BL

OR

POWER TO PLATFORM

POWER TO GROUND

GROUND

DATA LINK (HIGH)

DATA LINK (LOW)

BK

RD

WH

BL

OR

P2

EMERGENCY

J5 PIN1

J5 PIN4

J5 PIN5

STOP

U5

ELECTRONIC

CONTROL

MODULE

U3

PLATFORM CONTROLS

PRINTED CIRCUIT BOARD

J5 PIN2

D7

VOLTAGE

REGULATOR

12V DC

5V DC

PIN5

PIN6

PIN7

PIN8

PIN9

PIN10

PIN11

PIN12

PIN13

PIN14

PIN15

J2 PIN1

J2 PIN2

J2 PIN12

J2 PIN13

J2 PIN3

J2 PIN4

J5 PIN3

J2 PIN5

J2 PIN6

J2 PIN7

J2 PIN8

J2 PIN14

POUT1

PIN2

PIN3

PIN4

GY

YL

WH

BN

BL

PP

GY

OR

BK

RD

WH/BL

HALL EFFECT

GENERATOR

SW5

FUNCTION ENABLE

JC1

JOYSTICK

CONTROLLER

SW6

STEER

LEFT/ RIGHT

HORN BN5

STARTING AID BN3

ENGINE START BN2

HIGH TORQUE BN6

GENERATOR BN7

LPG SELECT BN14

HIGH IDLE BN4

LF OUTRIGGER ENABLE BN85

RF OUTRIGGER ENABLE BN86

LR OUTRIGGER ENABLE BN87

RR OUTRIGGER ENABLE BN24

LIFT FUNCTION BN9

ORGR AUTOLEVEL ENABLE BN20

SYSTEM STATUS L50

J1 PIN4

J1 PIN3

J1 PIN1

J1 PIN5

J3 PIN1

J3 PIN2

YL

BL

RD

BK

RD

BK

+

H1

ALARM

PLATFORM UP/DOWN TS20

-OR-

PLATFORM & OUTRIGGER

UP/DOWN

TS21

PLATFORM

CONTROLS

ES7184G

GS-2668 RT • GS-3268 RT Part No. 112657

June 2007

REV A

Section 6 • Schematics

Hydraulic Symbols Legend

Filter

Check valve

E

Engine

Fixed displacement pump

Dual acting cylinder

Single direction variable speed motor

Bi-directional variable speed motor

Counterbalance valve

Brake

Y44 Y1

Solenoid operated

2 position 2 way directional valve

Priority flow regulator

Solenoid operated

2 position 3 way directional valve

Relief valve

Solenoid operated

2 position 3 way directional valve

Proportional solenoid valve

Platform overload pressure switch

Shuttle valve

Single acting cylinder

Solenoid operated

2 position 2 way valve, normally closed

Solenoid operated

3 position 4 way directional valve

0.063 in

1.6 mm

Orifice with size

Hand pump

Pilot operated check valve with needle valve

Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 31

Section 6 • Schematics

Hydraulic Schematic

(from serial number GS6805-44771)

Part 1 of 2

November 2008

REV C

DA

Y29

DC

GENERATOR

MANIFOLD

3000 psi

206.8 bar

DB

4.5 gpm

17 L/min

BRAKE

BRAKE

RELEASE

MANIFOLD

AG

GENERATOR

(OPTION)

IN-B

OUTRIGGERS

(OPTION)

LEFT FRONT

OUTRIGGER

RIGHT FRONT

OUTRIGGER

Y35

CB

Y36

CA

0.063 in

1.6 mm

BC

OUT-B IN-R

Y44

BB

OUT-R

MANUAL

RELEASE

AH

B1

P1

HAND

PUMP

FAA

TEST 1

X

FX

TEST 2

X

BRAKE

FP

FJ

0.035 in

0.89 mm

Y2

FO

Y3

FF

STEER CYLINDER

LEFT RIGHT

S2 S1

Y4

10 psi

0.7 bar

FZ

FV

2800 psi

193 bar

2 gpm

7.5 L/min

200 psi

13.8 bar

FG

5 psi

0.3 bar

FH

P2

BD

Y40 Y39

OUTRIGGER

MANIFOLD

IN

2000 psi

137.8 bar

Y33

CD CC

Y34

BA

OUT

FAC

3500 psi

241.3 bar

FU

Y9

FUNCTION

MANIFOLD

LEFT REAR

OUTRIGGER

RIGHT REAR

OUTRIGGER

6.5 gpm

24.6 L/min

2 1

6.5 gpm

24.6 L/min

E

HYDRAULIC TANK

25 psi

1.7 bar

Note: 'alpha' callouts refer to components shown in the manifold illustrations.

Refer to the Repair Section.

6 - 32 GS-2668 RT • GS-3268 RT

HS0032D

HS7040B

Part No. 112657

November 2008

REV C

Section 6 • Schematics

Hydraulic Schematic

(from serial number GS6805-44771)

Part 2 of 2

Part No. 112657 GS-2668 RT • GS-3268 RT 6 - 33

Section 6 • Schematics June 2007

This page intentionally left blank.

6 - 34 GS-2668 RT • GS-3268 RT Part No. 112657

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 0800 180 9017

Phone

Fax

+49 422 149 1818

+49 422 149 1820

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 North America

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 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

Genie Brasil

Phone +55 11 41 665 755

Fax +55 11 41 665 754

Genie Holland

Phone +31 183 581 102

Fax +31 183 581 566

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.

Part No.

112657

Rev C2