Genie GS-3246 Service Manual - Rentalex

1 Service ManualPart No. 72972 September 2006 Rev B2 Genie GS-2046 and GS-2646 and GS- 3246 Part No. 72972 June 2003iiIntroductionImportantRead, understand and obey the safety rules andoperating instructions in the Genie GS-2032 andGS-2632 and GS-2046 and GS-2646 and GS- 3246 Operator's Manual before attempting anymaintenance or repair Manual provides detailed scheduledmaintenance information for the machine ownerand user. It also provides troubleshooting andrepair procedures for qualified mechanical, hydraulic and electricalskills are required to perform most , several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice PublicationsGenie Industries has endeavored to deliver thehighest degree of accuracy possible.

2 However,continuous improvement of our products is a Geniepolicy. Therefore, product specificationsare subject to change without are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other Us:PO Box 97030 Redmond, WA 98073-9730 : 1997 by Genie Industries72972 Rev BJune 2003 Second Edition, Second Printing" Genie " is a registered trademark of GenieIndustries in the USA and many other countries."GS" is a trademark of Genie Industries. Printed on recycled paperPrinted in Number InformationGenie Industries offers the following ServiceManuals for these models:TitlePart GS-2046 and GS-2646 and GS- 3246 Service Manual (before serial number 17408).

3 48339 Part No. 72972 Genie GS-2046 and GS-2646 and GS- 3246 June 2003iiiSafety RulesSection 1 Safety RulesDangerFailure to obey the instructions and safety rulesin this Manual and the Genie GS-2032 andGS-2632 and GS-2046 and GS-2646 and GS- 3246 Operator's Manual will result in death or of the hazards identified in theoperator s Manual are also safety hazardswhen maintenance and repair proceduresare Not Perform MaintenanceUnless:You are trained and qualified to performmaintenance on this read, understand and obey:- manufacturer s instructions and safety rules- employer s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable GS-2046 and GS-2646 and GS- 3246 Part No.

4 72972 June 2003 SAFETY RULESP ersonal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:Safety alert symbol used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious with safety alert symbol used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate without safety alertsymbol used to indicate thepresence of a potentiallyhazardous situation which, if notavoided.

5 May result in used to indicate operationor maintenance sure to wear protective eye wear andother protective clothing if the situationwarrants aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting orplacing loads. Always wear approved SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have an approved fireextinguisher within easy sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free ofdebris that could get into machine components andcause sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted.

6 Use only chains or straps thatare in good condition and of ample sure that fasteners intended for onetime use ( , cotter pins and self-lockingnuts) are not reused. These componentsmay fail if they are used a second sure to properly dispose of old oil orother fluids. Use an approved be environmentally safe .Be sure that your workshop or work areais properly ventilated and well 1 Safety RulesPart No. 72972 Genie GS-2046 and GS-2646 and GS- 3246 June 2003 Table of ContentsvIntroductionImportant OneSafety RulesGeneral Safety Rules ..iiiSection TwoSpecifications - Rev BMachine 2 - 1 Performance 2 - 2 Hydraulic 2 - 3 Manifold Component Specifications ..2 - 4 Hydraulic Hose and Fitting Torque 2 - 6 Section ThreeScheduled maintenance 3 - 1 Pre-delivery Preparation 3 - 3 maintenance Inspection 3 - 5 Checklist A procedures - Rev BA-1 Perform Pre-operation 3 - 6A-2 Perform Function 3 - 6A-3 Perform 30 Day 3 - 7A-4 Grease the Steer Yokes.

7 3 - 7 Genie GS-2046 and GS-2646 and GS- 3246 Part No. 72972 September 2006 TABLE OF CONTENTSviSection ThreeMaintenance procedures , continuedChecklist B procedures - Rev CB-1 Inspect the Batteries .. 3 - 8B-2 Inspect the Electrical 3 - 9B-3 Inspect the Tires and Wheels (including castle nut torque).. 3 - 10B-4 Test the Key Switch ..3 - 10B-5 Test the Automotive-style Horn (if equipped) .. 3 - 11B-6 Test the Drive 3 - 12B-7 Test the Drive Speed - Stowed 3 - 14B-8 Test the Drive Speed - Raised 3 - 15B-9 Perform Hydraulic Oil 3 - 16B-10 Replace the Hydraulic Tank Return Filter .. 3 - 16B-11 Check the Module Tray Latch Components ..3 - 17 Checklist C Procedure - Rev CC-1 Check the Scissor Arm Wear Pads .. 3 - 19 Checklist D Procedure - Rev AD-1 Test or Replace the Hydraulic Oil.

8 3 - 20 Part No. 72972 Genie GS-2046 and GS-2646 and GS- 3246 June 2003 TABLE OF CONTENTSviiSection FourRepair 4 - 1 Platform Controls - Rev B1-1 Circuit 4 - 21-2 Joystick 4 - 31-3 Controller 4 - 51-4 Software 4 - 13 Platform Components - Rev 4 - 162-2 Platform Extension .. 4 - 17 Scissor Components - Rev A3-1 Scissor Assembly, GS-2046 ..4 - 183-2 Scissor Assembly, GS-2646 ..4 - 243-3 Scissor Assembly, GS- 3246 ..4 - 323-4 Lift 4 - 42 Ground Controls - Rev B4-1 Manual Platform Lowering Cable, GS-2046 and GS-2646 ..4 - 464-2 Manual Platform Lowering, 4 - 474-3 Toggle 4 - 484-4 Control Relays .. 4 - 494-5 Tilt Level Sensor (before serial number 50444) ..4 - 504-6 Tilt Level Sensor (after serial number 50443) ..4 - 54 Genie GS-2046 and GS-2646 and GS- 3246 Part No.

9 72972 June 2003 TABLE OF CONTENTS viiiSection FourRepair procedures , continuedHydraulic Pump - Rev A5-1 Function 4 - 58 Function Manifold - Rev B6-1 Function Manifold Components(from serial number 17408 to 17481) .. 4 - 606-2 Function Manifold Components(from serial number 17482 to 36044) .. 4 - 626-3 Function Manifold Components(after serial number 36044) .. 4 - 646-4 Function Manifold Components - Models with Traction Control ..4 - 666-5 Valve Adjustments - Function Manifold .. 4 - 686-6 Platform Lift Relief Valve Manifold Components, GS- 3246 Models(before serial number 36045).. 4 - 756-7 Valve Adjustments - Lift Relief Manifold, GS- 3246 Models(before serial number 36045).. 4 - 766-8 Valve 4 - 78 Hydraulic Tank - Rev A7-1 Hydraulic 4 - 80 Steer Axle Components - Rev A8-1 Yoke and Drive 4 - 818-2 Steer 4 - 838-3 Steer 4 - 84 Non-steer Axle Components - Rev A9-1 Drive Brake.

10 4 - 85 Brake Release Hand Pump Components - Rev A10-1 Brake Release Hand Pump 4 - 86 Part No. 72972 Genie GS-2046 and GS-2646 and GS- 3246 June 2003 TABLE OF CONTENTSixSection FiveTroubleshooting Flow Charts and Fault 5 - 1 Fault Code Chart (after serial number 17407) - Rev A .. 5 - 3 ChartNumberChart Title1 All Functions Will Not Operate - Rev 5 - 42 Pump Motor Will Not Operate - Rev A .. 5 - 63 All Functions Inoperative, Power Unit Starts and Runs - Rev 5 - 84 Ground Controls Inoperative,Platform Controls Operate Normally - Rev A .. 5 - 95 Platform Controls Inoperative,Ground Controls Operate Normally - Rev A .. 5 - 106 Platform Up Function Inoperative - Rev A .. 5 - 117 Platform Down Function Inoperative - Rev A .. 5 - 128 Steer Left Function Inoperative - Rev A.