Genie GS-2646AV Installation and operating manual

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.
Contact Us:
Internet: www.genielift.com
E-mail: [e-mail]
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.
Copyright © 2016 by Terex Corporation
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
t.
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
e
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