Genie GS-2646AV Manuel d'installation et d'exploitation

Service and Repair Manual

Serial Number Range

GS-2646AV

from GS4612A-110000

from GS4616P-

138362 to

GS4616P-

141799

This manual includes:

Repair procedures

Fault Codes

Electrical and

Hydraulic Schematics

GS-2646AV 35

from GS46P-141800

For detailed maintenance

procedures, refer to the

appropriate Maintenance

Manual for your machine.

Part No. 1272218

Rev A2

September 2016

Service and Repair Manual September 2016

Introduction

ii GS-2646 AV • GS-2646 AV35 Part No. 1272218

Intr oduct io n Intr oduct io n

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate Operator's

Manual on your machine before attempting any

procedure.

This manual provides troubleshooting and repair

procedures for qualified service professionals.

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 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection and

scheduled maintenance.

Technical Publications

Genie 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.

Internet: www.genielift.com

E-mail: awp.techpub@terex.com

Find a Manual for this Model

Go to http://www.genielift.com

Use the links to locate Service Manuals,

Maintenance Manuals, Service and Repair

Manuals, Parts Manuals and Operator's Manuals.

1272218 Rev A, March 2016

First Edition, First Printing

Genie is a registered trademark of Terex South Dakota, Inc. in

the U.S.A. and many other countries. “GS” is a trademark of

Terex South Dakota, Inc..

September 2016 Service and Repair Manual

Introduction

Part No. 1272218 GS-2646 AV • GS-2646 AV35 iii

Revision History

Revision Date Section Procedure / Page / Description

A 3/2016

Initial Release

A1 5/2016 Repair Procedures 2-3, 2-4, 2-5, 2-6

Diagnostics H067 fault

A2 9/2016 Introduction Serial Number Legend

Reference Examples: Electronic Version

Click on any content or procedure in the Table of Contents to view

the update.

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Section – Schematics, Legends and schematics

Service and Repair Manual September 2016

Introduction

iv GS-2646 AV • GS-2646 AV35 Part No. 1272218

Serial Number Legend

To August 31, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial label (located on chassis)

6 Serial number (stamped on chassis)

From September 1, 2016

1 Model

2 Facility code

3 Sequence number

4 Serial label (located on chassis)

5 Serial number (stamped on chassis)

September 2016 Service and Repair Manual

Safety Rules

Part No. 1272218 GS-2646 AV • GS-2646 AV35 v

Section 1 Safet y Rul es

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.

Service and Repair Manual September 2016

Safety Rules

vi GS-2646 AV • GS-2646 AV35 Part No. 1272218

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 a 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 i

Be aware of potential crushing hazards

such as moving parts, free swinging or

unsecured components when lifting or

placing loads. Always wear approved

steel

-toed shoes.

Workplace Safety

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.

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases

and engine fuels. Alwa

ys 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 on

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.

September 2016

Table of Contents

Part No. 1272218 GS-2646 AV • GS-2646 AV35 vii

Introduction Introduction...........................................................................................................ii

Important Information .............................................................................................ii

Find a Manual for this Model..................................................................................ii

Revision History..................................................................................................... iii

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

Section 1 Safety Rules..........................................................................................................v

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

Section 2Specifications.......................................................................................................1

Machine Specifications...........................................................................................1

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

Hydraulic Specification...........................................................................................3

Hydraulic Component and Manifold Specifications................................................6

Hydraulic Hose and Fitting Torque Specifications .................................................6

Torque Procedure ..................................................................................................7

Section 3 Repair Procedures ...............................................................................................9

Introduction.............................................................................................................9

Platform Controls...............................................................................................11

1-1 Circuit Board...................................................................................................12

1-2 Joystick...........................................................................................................13

1-3 Platfrom Controls Alarm.................................................................................13

1-4 Platform Emergency Stop Button...................................................................14

Ground Controls.................................................................................................15

2-1 Software Revision Level.................................................................................16

2-2 Machine Setup ...............................................................................................17

2-3 Loading or Updating Machine Software.........................................................18

2-4 Using a Wi-Fi Router to Connect to the SmartLink Web Service Tool ..........23

2-5 Service Override Mode ..................................................................................25

2-6 Level Sensors ................................................................................................27

2-7 Manual Platform Lowering Cable...................................................................41

September 2016

Table of Contents

viii GS-2646 AV • GS-2646 AV35 Part No. 1272218

Hydraulic Tank ...................................................................................................43

3-1 Hydraulic Tank...............................................................................................43

Hydraulic Pump.................................................................................................. 44

4-1 Hydraulic Pump .............................................................................................44

How to Remove the Hydraulic Pump..............................................................45

Manifolds ............................................................................................................46

5-1 Function Manifold Components.....................................................................46

5-2 Powered Extension Deck Function Manifold Components ...........................48

5-3 Valve Adjustments – Function Manifold ........................................................49

5-4 Valve Coils.....................................................................................................52

Steer Axle Components ....................................................................................55

6-1 Yoke and Drive Motor....................................................................................55

6-2 Steer Cylinder................................................................................................56

6-3 Steer Bellcrank ..............................................................................................57

Non-Steer Axle Components............................................................................ 58

7-1 Drive Brake....................................................................................................58

Brake Release Hand Pump Components ........................................................59

8-1 Brake Release Hand Pump Components......................................................59

Scissor Components.........................................................................................60

9-1 Scissor Assembly ..........................................................................................61

How to Replace the Scissor Arm Wear Pads.................................................66

9-2 Lift Cylinder....................................................................................................67

Platform Components .......................................................................................69

10-1 Platform........................................................................................................69

10-2 Platform Extension.......................................................................................71

How to Remove the Manual Extension Deck .................................................71

How to Remove the Powered Extension Deck (if equipped)..........................72

10-3 Extension Deck Cylinder..............................................................................73

September 2016

Table of Contents

Part No. 1272218 GS-2646 AV • GS-2646 AV35 ix

Section 4 Diagnostics.........................................................................................................77

Introduction...........................................................................................................77

GCON I/O Map (with manual extension deck).....................................................79

GCON I/O Map (with powered extension deck)...................................................80

Operation Indicator Codes (OIC)..........................................................................82

Diagnostic Trouble Codes (DTC).........................................................................82

Troubleshooting "HXXX" and "PXXX" Faults.......................................................83

Fault Inspection Procedure ..................................................................................84

Type "HXXX" Faults .............................................................................................86

Type "PXXX" Faults..............................................................................................88

Type "UXXX" Faults .............................................................................................89

Type "FXXX" Faults..............................................................................................91

Type "CXXX" Faults .............................................................................................92

Section 5 Schematics..........................................................................................................93

Introduction...........................................................................................................93

Electrical Component and Wire Color Legends ...................................................94

Wiring Diagram Ground Controls.........................................................................96

Wiring Diagram Platform Controls........................................................................97

Limit Switch Legend .............................................................................................98

Electrical Symbol Legend...................................................................................100

Hydraulic Symbols Legend.................................................................................101

Hydraulic Component Reference.......................................................................102

Electrical Schematics – ANSI and CSA Models............................................103

Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with manual extension

deck) (from GS4612A-110000) ..................................................................104

Electrical Schematic • GS-2646 AV and GS-2646 AV35 (with powered extension

deck) (from serial number GS4612A-110000) ...........................................108

Electrical Schematic • GS-2646 AV and GS-2646 AV35 (foot switch option) (from

serial number GS4612A-110000)...............................................................112

Section 6 Hydraulic Schematics......................................................................................113

Hydraulic Schematic...........................................................................................113

Hydraulic Schematic, Powered Extension Deck Manifold..................................114

Ce manuel convient aux modèles suivants

Table des matières

Autres manuels Genie Système de levage

Genie

Genie Z-30/20N Manuel utilisateur

Genie

Genie GTH-4013 EX Manuel utilisateur

Genie

Genie SX-180 Manuel d'installation et d'exploitation

Genie

Genie GTH-2506 Stage A Manuel utilisateur

Genie

Genie Z-60/34 Manuel utilisateur

Genie

Genie Lift Guard GRC-12 Manuel utilisateur

Genie

Genie Z-45/25 Manuel utilisateur

Genie

Genie Z-25/8 Manuel utilisateur

Genie

Genie S-45 XC Manuel d'installation et d'exploitation

Genie

Genie GS-2668 RT Manuel utilisateur

Genie

Genie S-80 Manuel utilisateur

Genie

Genie GTH-844 Manuel d'installation et d'exploitation

Genie

Genie TZ-34/20 Manuel utilisateur

Genie

Genie S-60 HC Manuel utilisateur

Genie

Genie Super Tower ST-20 Manuel utilisateur

Genie

Genie GS-1930 Manuel utilisateur

Genie

Genie AWP-15S Manuel utilisateur

Genie

Genie GS-2032 Guide de configuration

Genie

Genie AWP Super Series Manuel utilisateur

Genie

Genie GS-3384 Manuel utilisateur

Genie

Genie GS-3384 Manuel d'installation et d'exploitation

Genie

Genie Z-45/25 Manuel utilisateur

Genie

Genie GR-20J Manuel utilisateur

Genie

Genie Z-30/20N Manuel d'installation et d'exploitation

Manuels Système de levage populaires d'autres marques

morse

morse 82H-124 Manuel utilisateur

Braun

Braun NL955 Series Manuel utilisateur

haacon

haacon 1889.10 Manuel utilisateur

Protekt

Protekt AT 252 Manuel utilisateur

R. Beck Maschinenbau

R. Beck Maschinenbau HS 600 Manuel utilisateur

Nova Technology International, LLC

Nova Technology International, LLC NAS Series Manuel utilisateur

Screen Technics

Screen Technics INTERFIT Vertical Up Lift Manuel utilisateur

Mortuary Lift

Mortuary Lift ULTIMATE 1000 Manuel utilisateur

Custom Equipment

Custom Equipment Hy-Brid 3 Series Manuel de programmation

Custom Equipment

Custom Equipment Hy-Brid Lifts 2 Series Manuel de programmation

Hy-Brid Lifts

Hy-Brid Lifts HB-P3.6 Manuel de programmation

BERG

BERG BeNomic EasyLeaf Manuel utilisateur

Powermate

Powermate LiftGate LG-3 Manuel utilisateur

Snorkel

Snorkel TM12 Series Manuel utilisateur

Terberg

Terberg OMNIDEKA Manuel utilisateur

Harmar Mobility

Harmar Mobility AL625 Mode d'emploi

Rotary

Rotary SPO16 Manuel utilisateur

Ricon

Ricon Mirage F9T Manuel utilisateur