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1. KS1 P1 212 Q EMERGENCY STOP 04 gt x 1 PLATFORM CONTROL 4 d 1 3 Hi oe i GROUND E 4 20 2 D ABS 1 1 ABS T PS2 PLATFORM OVERLOAD PRESSURE SWITCH AB20 CR41 CR1 CR23 6 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY SYSTEM POWER HORN IGNITION START DOWN OF ABT LS6 PLAT 86 2 86 2 86 A 86 30 4 86 86 DOWN wr 85 ef as 87 85 85 M 857 et SWITCH n 4 n 1 HEH 5 em 992899 BLS 5 9 ae a Posee uer e eec EXCT o J1 C7 BN23 BN91 4264 0 lt AUXILIARY DOWN AUXILIARY DOWN J2 B9 ENABLE CR15 180 5 5 STARTING 4 AID WORK 12 HIGH IDLE LIGHTS NC 86 304 7 N C LS24 LS25 B1 e etwa 86 30 MAXIMUM LOAD SENSE tP t i 5 A HEIG
2. QD4 QD3 P2 Q EMERGENCY WH RD 4 4 4 BK POWER TO PLATFORM STOP RD WH 7 Rb POWER ro GROUND 2 31 BL 1 1 1 1 WH GROUND BK r 2 2 2 2 BL DATALINK HIGH OR 5 5 1 1 5 5 5 1 OR DATA LINK LOW 1 OUTRIGGERS OPTION J5 PIN2 2 D7 PLATFORM CONTROLS VOLTAGE cipio PRINTED CIRCUIT BOARD REGULATOR S8 2 TILT LEVEL J2 PIN1 SENSOR a YL HALL EFFECT 9 7 ERATOE JC1 9 I 9 42 PIN12 JOYSTICK 1812 1813 1814 1815 4 8 e CONTROLLER n0 9 J2PIN13 O LF RF LR RR m O RIG O RIG J2PIN3 UMIT LIMT LIMT o lt o SWITCH SWITCH SWITCH SWITCH 5 E 9 SW5 1 S 5 J5 W6 gt gt NO NOS O
3. KS1 1 Bi EMERGENCY STOP 21 oT RS T PLATFORM CONTROL 44 HERE 1 oe GROUND LIEST erri EE d ABI CB2 20a 7 AB7 ABS ABS CR41 1 CR23 N C CONTROL CR42 CR5 CR8 ENGINE AUXILIARY 1 HORN IGNITION START DOWN G6 OF HOUR METER 156 1 PLAT 86 30 O 86 30 2 86 30 5 86 30 4 86 30 8 86 30 6 DOWN ERI 85 870 5 85 a 87 771 85 s SWITCH US FEE e em 99930 5 19 L30 1 N 5 WORK LIGHTS Ws um ur et py yn 3 07 BN23 BN91 J2 C4 AUXILIARY DOWN AUXILIARY DOWN J2 B9 ENABLE U19 8 2 uu ulis CR15 CR4 M STARTING HIGH IDLE 4 AID O 86 A AN im 165 85 87 87A 85 87 87A 4700 uF Y7A Tic A T t 0 dat dtt 1 Q7 cox A CHOKE HIGH IDLE SOLENOID SOLENOID c a M
4. QD4 QD3 STOP BK ES C BK POWER TO PLATFORM A A A A RD POWER TO GROUND B B B B WH GROUND D D 7 D D 4 BL DATA LINK HIGH E E G8 i YL DATA LINK LOW DIAGNOSTIC fe DISPLAY DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR s piles eps eee oe eee Gia oes ek 7 11 MIT a SS memi ENABLE JC1 gel aes M d t 7 6 PLATFORM PLATFORM EXTENSION F 7 OR POTENTIOMETER DOWN 9 UP DECK 8 WH BK WH YL 71 T E LEVEL o ow SENSOR SW5 SWG RIGHT N C N C 1 CIRCUIT WH BL FUNCTION ENABLE T TS66 PIN18 O m 2 5 j 1 4 I id pin15 c E S7 WH gt 5 2 LEVEL L 4 E SENSOR MEME i PLATFORM CONTROLS BN MEMBRANE DECAL Elz Pour o POWER LED L19 l Pour o E LPG LED 122 5 5 5 5 5 555555 E POUT4 lt lt 4 FAULT LED L25 2 9 POUTS o 4 GENERATOR LED 12
5. dielelelelelelele 14 Y Bi J2 OR RD WH BN 6 NE TS20 4 BL OR mE TS21 J e e TS20 PLATFORM UP DOWN TOGGLE SWITCH MODELS WITHOUT OUTRIGGERS TS21 PLATFORM UP DOWN OUTRIGGER UP DOWN TOGGLE SWITCH MODELS WITH OUTRIGGERS Genie GS 2668 RT GS 3268 RT Part No 52302 Section 6 Schematics July 2007 Electrical Schematics Abbreviation and Wire Color Legends REV ELECTRICAL SCHEMATIC LEGEND ELECTRICAL SCHEMATIC LEGEND WIRE COLOR ription Description LEGEND attery ote B1 Engine start N C Normally closed Item Description B4 Auxiliary platform down N O Normally open BN Button P Power ac 1 Engine stop Emergency stop button at ground controls BR Brown BN2 Engine start P2 Emergency stop button at platform controls GN Green Glow plug PS2 Platform overload pressure switch OR Orange High idle Q Electro mechanical solenoid P Purple BN5 Horn Q1 1
6. QD3 P2 EMERGENCY WHIRD 4 i i 4 4 BK POWER TO PLATFORM STOP RD WH 7 Rb POWER ro GROUND 2 31 BL 1 1 1 1 WH GROUND BK 2 2 2 2 BL DATALINK HIGH OR 5 5 1 1 5 cea 5 5 1 OR DATA LINK LOW 7 OUTRIGGERS OPTION J5 PIN2 c qe D7 ABS 2 PLATFORM CONTROLS VOLTAGE sy pc PRINTED CIRCUIT BOARD REGULATOR S8 l 2 AXIS TILT LEVEL J2 PIN1 SENSOR SSN YL HALL EFFECT E 9 J2PIN2 O X GENERATOR JC1 Q 3 v Q J2pn12 o JOYSTICK LS12 LS13 LS14LS15 BN CONTROLLER n0 9 J2PIN13 LF RF LR RR O RIG J2PIN3 LIMT UMT o lt mo IBI SWITCH SWITCH SWITCH SWITCH ror x upon M 125 J5PIN3 O SW5 E SW6 n NO 4j NOS NO 255 o FUNCTION ENABLE Fl 2 STEER 4 2 BK i X LEFT RIGHT 1 AB23 42 PING O gt J2PIN7 27 1 26 17 16 Trag L J2PIN8 O J2 PIN14 c c c c c c i oC C 7 9 m g g 8 2 2 221 POUTI PIN2 HORN BN5 U5 PINS STARTING AID BN3 ELECTRONIC CONTROL PIN4 ENGINE START BN2 c 5 c
7. NEUE E 004 QD3 WHIRD 4 4 1 4 4 BK POWER TO PLATFORM RD WH 3 Rb POWER GROUND 89 31 BL 1 1 1 1 H WH GROUND BK i 2 2 2 2 BL DATALINK HIGH OR 5 5 6 T 5 5 1 OR DATA LINK LOW OUTRIGGERS OPTION J5 PIN2 2 2 D7 PLATFORM CONTROLS VOLTAGE sy pc PRINTED CIRCUIT BOARD REGULATOR 2 AXIS TILT LEVEL J2 PIN1 SENSOR Jo RIND YL 41 HALL EFFECT 2 WH 7s GENERATOR JOYSTICK 2 1512 1 13 1 14 1 15 4 8 CONTROLLER 8 2 J2 PIN13 BN LF RF LR 9 LL 1 J2 PINS LIMT LIMT o lt JADNA SWITCH SWITCH SWITCH SWITCH dq 2 E 5 UNE GY SW5 swe 0 NO 4 NOt NOS BES OWENS OR FUNCTION ENABLE lt 2 STEER ZAA BK 4 LEFT RIGHT 1 1 23 18824 L J2 PING zi E J2 PIN7 BD AB27 1 26 17 16 T Bz L J2 PIN8 1 J2 PIN14 c lt c c c c Ca c toc lt x T T 25 pp 9 9 9 Q 5 25858 i POUTI PIN2 HORN BN5 U5 PIN3 STARTING AID BN3 ELECTRONIC 5 CONTROL PIN4 ENGINE START BN2 c c c c es MODULE x rs d T 5 9 amp o 6 HIGH TOR
8. BN12 BN13 ALARM FUNCTION FUNCTION TS20 ALARM FUNCTION FUNCTION PLATFORM ENABLE ENABLE HIGHSPEED LOW SPEED UP DOWN HIGHSPEED LOW SPEED TS20 UTTOI BUTTON TOGGLE BUTTON BUTTON PLATFORM UP DOWN WH SWITCH TOGGLE SWITCH MODELS WITHOUT OUTRIGGERS OR TS21 PLATFORM UP DOWN OUTRIGGER UP DOWN TOGGLE SWITCH MODELS WITH OUTRIGGERS TO COIL CORD ASSEMBLY ic TO COIL CORD ASSEMBLY Gasoline LPG models Gasoline LPG models before serial number 1241 after serial number 1240 and and Diesel models Diesel models before serial number 1055 after serial number 1054 Genie COMPANY 6 6 GS 2668 RT GS 3268 RT Part No 52302 Section 6 Schematics July 2007 Wiring Diagram Platform Control Box from serial number GS6803 42382 to GS6805 44770 REVA COIL CORD ASSEMBLY gt S H1 ALARM _ BK e NC 1 RD e 6 Qo P2 EMERGENCY STOP OR JC1 JOYSTICK WH CONTROLLER GY ate 4 J3 BK U 1 PLATFORM CONTROLS CIRCUIT BK BOARD PP YL WH BL
9. DIESEL MODELS WITH enie R15 JOYSTICK 26 9 5K CONTROLLER 8 WH BK WH YL sw5 FUNCTION ENABLE T pinis WHBL 2 4 I E e BK PLATFORM CONTROLS uM MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 i LIFT ERROR INDICATOR LED L57 POUT4 A 4 FAULT LED 125 POUTS 2 lt ES 4 GENERATOR LED L27 POUT6 O i HIGH TORQUE LED 121 POUT8 O 4 HIGH IDLE LED L23 L NT PIN5 O ENGINE STOP BN1 PING O e ENGINE START BN2 T PIN10 O 4 AUTO LEVEL BN20 E PIN19 O 4 HIGH TORQUE LF OUTRIGGER BN171 PIN23 22 4 HIGH IDLE BN4 PIN24 O RROUTRIGGER BN24 E OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 e PIN25 e GENERATOR RF OUTRIGGER BN18 i Ed PIN29 O gt STARTING AID WH 2 LIFT ENABLE HIGH BN12 JP PIN2 BL ENABLE LOW BN13 PINs o P UP YL PLATFORM amp OUTRIGGER UP DOWN 1621 RD Pouno H1 BK ALARM PIN11 PLATFORM CONTROLS OUTRIGGERS GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 77 Section 6 Schematics Ju
10. DIESEL MODELS WITH enie A TEREX COMPANY R15 JOYSTICK 26 9 5K CONTROLLER 8 WH BK WH YL sw5 FUNCTION ENABLE T pinis WHBL 2 4 I E e BK PLATFORM CONTROLS uM MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 i LIFT ERROR INDICATOR LED L57 POUT4 A 4 FAULT LED 125 POUTS 2 lt ES 4 GENERATOR LED L27 POUT6 O i HIGH TORQUE LED 121 POUT8 O 4 HIGH IDLE LED L23 L NT PIN5 O ENGINE STOP BN1 PING O e ENGINE START BN2 T PIN10 O 4 AUTO LEVEL BN20 E PIN19 O 4 HIGH TORQUE LF OUTRIGGER BN171 PIN23 22 4 HIGH IDLE BN4 PIN24 O RROUTRIGGER BN24 E OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 e PIN25 e GENERATOR RF OUTRIGGER BN18 i Ed PIN29 O gt STARTING AID WH 2 LIFT ENABLE HIGH BN12 JP PIN2 BL ENABLE LOW BN13 PINs o P UP YL PLATFORM amp OUTRIGGER UP DOWN 1621 RD Pouno H1 BK ALARM PIN11 PLATFORM CONTROLS OUTRIGGERS GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 57 July 2007 REV B STOP P1 E
11. 3 30 0 2 Replace the Hydraulic Tank Return Filter 3 31 D 3 Perform Engine Maintenance Perkins 403C 11 Models 3 32 D 4 Perform Engine Maintenance Kubota DF752 Models 3 32 0 5 Perform Engine Maintenance Kubota Models 3 33 D 6 Perform Engine Maintenance Kubota D905 Models 3 33 Checklist E Procedures E 1 Test or Replace the Hydraulic 3 34 E 2 Perform Engine Maintenance Perkins 403C 11 Models 3 35 E 3 Perform Engine Maintenance Gasoline LPG Models 3 36 E 4 Perform Engine Maintenance Perkins 403C 11 Models 3 36 Genio Part No 52302 GS 2668 GS 3268 RT ix July 2007 SSS SSS TABLE OF CONTENTS Section 4 Rev Repair Procedures 4 1 C Platform Controls 1 1 Girc lt Boards epe ne ene abe edd 4 2 1 2 Joystick 4 3 1 3 Function Speed Tuning before serial number GS6803 42382 4 5 1 3 Software Configuration before serial number GS6803 42382 4 10 A Platform Components 2 1 du 4 14 2 2 PlatformiEXtenslon uac iiic rie tet eee ave Ecc 4 15 B Scissor Components 3 1 Scissor Assembly GS 2668
12. 4 18 3 2 Scissor Assembly GS 3268 4 24 3 3 4 31 3 4 Lift Gylinder S iioi etat eer tnter 4 32 D Kubota D905 Engine 4 1 Timing Adjustment 4 35 4 2 d 4 35 4 3 Engine RPM n te rere eed Cre eter 4 35 4 4 Flex a aeter pie deme e 4 36 4 5 Coolant Temperature and Oil Pressure Switches 4 37 Genie x GS 2668 RT 65 3268 RT Part No 52302 July 2007 p 9 TABLE OF CONTENTS Section 4 Rev Repair Procedures continued C Kubota DF750 DF752 Engine 5 1 Tming AdJUstiTignt uoo RP rere ie eet 4 38 5 2 Carburetor Adjustment Gasoline LPG Models 4 38 5 3 Choke Adjustment Gasoline LPG Models 4 38 5 4 Flex Plate noni po n Rd ead e bed ee 4 38 5 5 Coolant Temperature and Oil Pressure Switches 4 38 b 6 rer erede raa edad eL E aa 4 39 B Perkins 403C 11 Engine 6 1 Engine RPM cbe E aree E ea ates 4 40 62 TIMING ACJUSIIMONE retten d Fre eren 4 40 63 Flex Plate rit i n t eee ee 4 41 6 4
13. QD4 QD3 P2 Q EMERGENCY WH RD 4 4 4 BK POWER TO PLATFORM STOP RD WH 7 Rb POWER ro GROUND 2 31 BL 1 1 1 1 WH GROUND BK r 2 2 2 2 BL DATALINK HIGH OR 5 5 1 1 5 5 5 1 OR DATA LINK LOW 1 OUTRIGGERS OPTION J5 PIN2 2 D7 PLATFORM CONTROLS VOLTAGE cipio PRINTED CIRCUIT BOARD REGULATOR S8 2 TILT LEVEL J2 PIN1 SENSOR a YL HALL EFFECT 9 7 ERATOE JC1 9 I 9 42 PIN12 JOYSTICK 1812 1813 1814 1815 4 8 e CONTROLLER n0 9 J2PIN13 O LF RF LR RR m O RIG O RIG J2PIN3 UMIT LIMT LIMT o lt o SWITCH SWITCH SWITCH SWITCH 5 E 9 SW5 1 S 5 J5 W6 gt gt NO NOS OR FUNCTION ENABLE 7 2 STEER 1 1 BK i X LEFT RIGHT 1 823 ABBA Qoo 2 a gt J2PIN7 AB27 AB26 16 Tasas fABT L J2PIN8 O 1 J2 PIN14 c c c c c c i oC C 7 9 m g g 8 2 2 8 8 POUTI PIN2 HORN BN5 U5 STARTING AID ELECTRONIC S a CONTROL PIN4 ENGINE START BN2 lt
14. PLATFORM GROUND 8 17188 CR43 GROUND POWER TO ECM 1 85 86 CR25 CR1 BN23 4 ENGINE 30 ENGINE RUN START AUXILIARY 86 PLATFORM T 85 186 DOWN B CR8 GS 3268RT C 12v be 6 85 87 30 FUEL TS52 TS56 554 85 86 CR15 I 30 GLOW gt 9 12 PLUG 3 5 e E 85 86 9 20A CR4 30 HIGH IDLE ina SEER O 985835 amp d 1 9 ELECTRONIC CONTROL MODULE 86 amp 1 o h T L2 8 9 NR g 8 2 B1 1 12v pc Te T 86 127 ILL E Aie 21 li 1 304 85 Xon 17 FII E Y 4 T x pi 4 8 a 142 EX x 5 24 NE FB1 COM BBE B1 M3 D1 F9 Q8 G6 U32 2 Y7 Y7A H1 FB1 Swi SW2 L41 L42L27 Y29 2 5 85 8 48888 o a 5 2 v a E d og g 9 d A24 Q9 gd o N gt 21 m o lt z Z o c c lt 2 2 D m m 2 3 5 5 Lu 2 m m In 2 58 gt m m m 9 2 2 d gt gt 8 2 9 m 3 r 8 lt 5 m mea d d s F9 ADDED AFTER 5 9 I SERIAL NUMBER 38365 2 5 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7140C GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics REV B E
15. BATTERY 8 aul WT No 4 20A i 1 17 jo oo E tr de HYDRAULIC 112 OIL COOLER OPTION SENSOR MODELS WITHOUT BATTERY OUTRIGGERS 23 M1 G7 LEVEL wu t rs c 125 05 ELECTRONIC CONTROL MODULE 5 5 s lt c e ee 28 Loi gt F 5 S 9 9 5 o zi 5 5 8 9 m S 9 22 ABI 7 1 4 4 Y4 Y1 Y1B Y6 Y6A Y9 Q2 Q1 2 X X X LY d 4 4 4 4 l p Wwe cf Xi SEK 5 Sx 08 Sw2 SW1 H5 FB1 1 Y2 Y5 Y5A Y29 4 4 4 4 4 4 4 4 4 2 g g 5 o5 3 48 amp E B B2 2 a 5 d 8 3 8 9 9 9 2 5 9 gt m m 2 2 3 gt 2 2 3 m 5 m o lt v 8 E m Z2 m 2 29 Z p 28 2 2 3 23585858 855 8 RZS gag gp m 2 m 2 gt y v D T OF gt 2 In 4 o o 2 2 gt m 2 lt m zd 34 m S5 2 o A J gt 2 2 mn m 2 lt o S og g Z B gt fl g mos 5 PF h m mn n 5
16. 6 5 A Wiring Diagram Platform Control Box before serial number GS6803 42382 6 6 A Wiring Diagram Platform Control Box from serial number GS6803 42382 to 56805 44770 6 7 A Electrical Schematics Abbreviation and Wire Color Legends 6 8 A Electrical Symbols 6 9 C Electrical Schematic Gasoline LPG Models before serial number 21161 6 10 C Electrical Schematic Gasoline LPG Models from serial number 21161 to 21837 sss 6 12 C Electrical Schematic Gasoline LPG Models from serial number 21838 to 38464 6 14 Genie Part No 52302 GS 2668 RT GS 3268 RT xiii July 2007 TABLE OF CONTENTS Section 6 Rev Schematics continued Electrical Schematic Gasoline LPG Models from serial number 38465 to 41199 Electrical Schematic Gasoline LPG Models from serial number 41200 41823 Electrical Schematic Gasoline LPG Models from serial number 41824 to 956803 42381 Electrical Schematic ANSI Models with Gasoline LPG Power from serial number GS6803 42382 to GS6805 43594 Electrical Schematic A
17. 8 WH BK WH YL sw5 FUNCTION ENABLE T pinis WHBL 2 4 I E e BK PLATFORM CONTROLS uM MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 i LIFT ERROR INDICATOR LED L57 POUT4 A 4 FAULT LED 125 POUTS 2 lt ES 4 GENERATOR LED L27 POUT6 O i HIGH TORQUE LED 121 POUT8 O 4 HIGH IDLE LED L23 L NT PIN5 O ENGINE STOP BN1 PING O e ENGINE START BN2 T PIN10 O 4 AUTO LEVEL BN20 E PIN19 O 4 HIGH TORQUE LF OUTRIGGER BN171 PIN23 22 4 HIGH IDLE BN4 PIN24 O RROUTRIGGER BN24 E OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 e PIN25 e GENERATOR RF OUTRIGGER BN18 i Ed PIN29 O gt STARTING AID WH 2 LIFT ENABLE HIGH BN12 JP PIN2 BL ENABLE LOW BN13 PINs o P UP YL PLATFORM amp OUTRIGGER UP DOWN 1621 RD Pouno H1 BK ALARM PIN11 PLATFORM CONTROLS OUTRIGGERS GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 65 July 2007 REV B STOP P1 EMERGENCY 7A TS54 TS56 TS52 HIGH IDLE GLOW PLUG START J4 A4 J4 A3 ELECTRONIC CONTROL MODULE J2 A5 J4 A5
18. AUTOMOTIVE STYLE HORN I OPTION o WORK LIGHTS OPTION 8 HIGH IDLE SOLENOID CR1 ENGINE START Cj CHOKE G6 GROUND GROUND n Wil LU m gt 4 2 HOURMETER 4 2 m S DISTRIBUTOR o 2 SPARK PLUG S IGNITION COIL ALTERNATOR i AUXILIARY PLATFORM CB1 G5 3268RT ONLY 20A 2 ENGINE STARTER 4 7 ip BATTERY 12V DC 501165 Tre oc t5 ui lim IO pe 2 2 I ue gt 9 Ik OB enie COMPANY GS 2668 GS 3268 RT ATE Part No 52302 6 18 Part 2 of 3 Section 6 Schematics Electrical Schematic Gasoline LPG Models from serial number 38465 to 41199 July 2007 REV C s mee er oc O2 a O Gl TINN 1 J1 C7 C8 o 8 a 2 Be IO 688 m 8 Sg Lu ga
19. S PLATFORM CONTROL Jd 71 81 GROUND CONTROL 4 ABl CB2 20a jAB3 1 PS2 Y PLATFORM OVERLOAD t PRESSURE SWITCH AB20 CR41 eas GRE CR1 CR23 G sd CONTROL ENGINE AUXILIARY METER SYSTEM POWER HORN IGNITION START DOWN OF EJ LS6 1 PLAT 86 8 86 2 86 86 39 86 N 86 DOWN m 85 ef 85 85 85 85 85 SWITCH ABZ US SEEEEE 555 em 982899 BLS 5 8 PER c nsu 31 67 BN23 BN91 J2 C4 0 AUXILIARY DOWN AUXILIARY DOWN ENABLE 1 J2 B9 3 5 CR15 d eT STARTING e AID CR4 NC n n HIGH IDLE LIGHTS B1 a 7 LS24 LS25 MAXIMUM LOAD SENSE zat cat wt wal 86 HEIGHT DELAY 1 026 LIMIT SW LIMIT SW p 7 14 u ao 9 29 1 9I CR77 5 4 DOWN 85 87 87 DOWN Y7A Y10A d 7 ta C5 a 4700 uF 5 dud 7 1 GEI 1Q3 X X vv A 1 SoLENOIDI HIGH IDLE Y8 Y7 Y10 ERES 2 5 sS 42 S 5 2 S amp MESS 95 5 x gt 1 S 9 N d 9 o E 2 gt lt gt gt o 2 1 gt g
20. Section 6 Schematics Electrical Schematic Diesel Models from serial number 40174 to 40939 July 2007 REV B pcc zo pc J1 C7 C8 5 m 1 85 69 xa J2 B10 I J2 A6 J2 C1 C10 4 z B YL as l 42 83 55 AUTO LEVELING Q z DATA LINK BK m J2 g1 22 XO SENSOR RD elu Zz GROUND FROM PLATFORM j3 g 22810 m l 3 OUTRIGGER EXTEND z D gt SLOW I D J8 B5 J1 B7 N S OUTRIGGER RETRACT 2 o 4 4 T D gt sa Hers 9 gt lt d 3 z 7 86 N X OUTRIGGER EXTEND o xd xs RIGHT REAR 188 OUTRIGGER zs 2 d 5 gt lt LEFT REAR E 2 weet OUTRIGGER gt lt E 699 6 RIGHT FRONT 2 Qete Y Ji B5j N 2 OUTRIGGER 2 o gt lt LEFT FRONT J2 A8 S OUTRIGGER 7 19 9 SE 8 Jis PROPORTIONAL n gt FLOW CONTROL gt lt J1 A12 DRIVE PARALLEL e i 8 42 7 lt 2 20 JI ATI DRIVE PARALLEL e lt 2d gt
21. CR8 TERMINAL 30 BATTERY 4 8 aid 25 N 4 30 88 Ux CR17 wd HYDRAULIC 112 OILCOOLER A e OPTION LEVEL 57 SENSOR A 1 MODELS WITHOUT BATTERY p QUTRIGGERS 823 89 ABT rs c gt uU N a U5 m ELECTRONIC CONTROL MODULE 5 5 f 525 4 5 5 gt gt 9 9 N 5 o zi N E 5 5 8 9 22 ABS 4 n YA Y1 Y1B Y6 Y6A Y9 gt AUG 1 Mr Q EX 1 1 SW2 SW1 5 FB1 Y1A Y2 Y5 Y5A Y29 4 4 4 4 n 4 n Q X T lt lt lt lt lt lt lt lt lt lt lt lt m e 82 EP am 06 85 9 559 3 3 2 5 i o Q gt m 2 2 2 gt 2 2 2 9o m S m gt m m lt E z lt 38 2 3 5 m A T7 8 m gt 5 B 2 gt T T E m a 2 04 gt 2 m n 2 o o 2 gt gt m 2 lt m zd o 2 a gt D 2 B m 2 lt o 2 ES gt gt B m 22 2 m z gt m 2 gt RP 5 5 m m o 2 m 2 8 o zs x E 2 gt m gt o 3 I 2 E g 2 2 9 NOTE ES7162A Part No 52302 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Genie bebe GS 2668 RT GS 3268 RT Section 6 Schema
22. o 9 S x PIN14 ORGR AUTOLEVEL ENABLE BN20 i 4 i 4 E X o 35 1 2 f 5 a m o o o m PIN15 O SYSTEM STATUS L50 z 2 m m m m m a 2 2 2 2 g m 2 1 R 5 7 o menmie 8 m 9 0 1 S E E 5 gt 5 2 fu PLATFORM UP DOWN TS20 8 Q o 5 o EJ J1 PIN OR g O m 4 5 PLATFORM amp OUTRIGGER m m UP DOWN J 7 m z 0 90 dr L 4 Ji PINS o rS I MACHINE SHOWN IN THE STOWED pL ND PLATFORM POSITION WITH THE POWER OFF CONTROLS ES7184C enie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics REVA This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 97 Section 6 Schematics gt 7 1 1 7 1 1 2 Hydraulic Schematics Component Call out Legend HYDRAULIC COMPONENT LEGEND Item Function A Drive circuit directs oil to left front and right rear wheels motors B Drive circuit directs oil to right front and left rear wheels motors Check valve drive speed select circuit D Check valve prevents engine from running backward when on an incline and reversing direction of travel Check valve steer circuit Check valve proportional circuit Relief valve pump
23. Diesel Models from serial number 40940 to 41199 Electrical Schematic Part 1 of 3 Section 6 Schematics PLATFORM GROUND KS1 D ALTERNATOR GROUND AUXILIARY PLATFORM tn amp ENGINE STARTER m BATTERY 12V DC oc mE iurc IO z I SE Ls ure zo oQ9o 6 66 Part 2 of 3 Section 6 Schematics Electrical Schematic Diesel Models from serial number 40940 to 41199 July 2007 REV B Au W pcc zo pc J1 C7 C8 5 B IO 1 85 5 ul 2 a J2 B10 J2 A6 J2 C1 C10 4 z B YL DATAUINI CY YE 313 J2 B3 ou5 BK AUTO LEVELING Q z DATAUNK BK a4 18 2 0 SENSOR o RD elu Zz GROUND FROM PLATFORM j3 g 22810 m l 3 OUTRIGGER EXTEND z D gt SLOW I D j J3 B5 J1 B7 N 8 OUTRIGGER RETRACT lt T 4 4 T D gt sa Hers 9 gt lt d 3 z 7 86 N X OUTRIGGER EXTEND o xd xs RIGHT REAR 188 OUTRIGGER zs 2 z t d
24. p eo C steer rocker switch SW6 horn button BN5 platform extend retract enable BN16 OR outrigger enable button BN16 om Models without outriggers Press and hold the horn button and platform extend retract enable button then turn the key switch to platform controls Models with outriggers Press and hold the horn button and the outrigger enable button then turn the key switch to platform controls Result The diagnostic display window at the ground controls will show PS Note The PS showing in the diagnostic display window indicates that the ECM is in the programming mode Genie GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV PLATFORM CONTROLS 4 Release the horn button and the platform extend retract enable button or outrigger enable button 5 Press the horn button to show the maximum raised drive speed percentage 6 To increase or decrease the raised drive speed press and hold the horn button while using the steering rocker switch to adjust the percentage The percentage will be seen in the diagnostic display window Factory percentage settings Raised drive speed Gasoline LPG models 22 Diesel models 28 7 Release the horn button 8 Turn the key switch to the off position to save the settings 9 Confirm the raised drive speed of the machine Refer to Maintenance Procedure B 11
25. NC m NG e x HIGH IDLE LIGHTS LS24 LS25 B1 C ABI MAXIMUM LOAD SENSE t zat cat wt wal 86 HEIGHT DELAY 1 026 e pee LIMIT SW LIMIT SW p and 857 14 u ao 9 om I CR77 5 4 VUL 8 et 1 t n dem 1 PS EARS lt 4700 uF 5 dud 7 1 GEI 1Q3 X X vv A 1 SoLENOIDI HIGH IDLE Y8 Y7 Y10 i t p g s 2 t 554 S m MESS 95 5 AE 1777 M 3d 33 D cC o 9g oif o z E gt ee lt gt gt o 2 1 gt gt wr 5 9 3 3 rm 9 2 z E 858 d E 2 2 2 pu gt 5 s m m a 5 f g 5 9 55 2 2 5 20 20 gt m 2 o T 85 4 lt m d I e sz 525 d m 9 ES 8 9 5 g x m Q 2 lt d Es gt 2 m a o 2 z m 5 m g T z o z o sa z 2 9 gt gt MACHINE SHOWN IN THE STOWED ES7161A POSITION WITH THE POWER OFF ES7183A Genie A TEREX COMPANY 6 38 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics REV B Electrical Schematic CE Models with Gasoline LPG Power from serial number GS6803 42382 to GS6805 43594 Part 2 of 3 CR8 TERMINAL 30 ABZ
26. D D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS VOLTAGE REGULATOR PRINTED CIRCUIT BOARD REGULATOR BN R15 JOYSTICK gt 5K CONTROLLER POTENTIOMETER LPP 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE LERIZRIGHIT PIN18 WHEE 4 PLATFORM CONTROLS MEMBRANE DECAL POUT4 POWER LED L19 POUTS POUT6 29 FAULT LED 125 GENERATOR LED 127 PINS O 6 HIGH TORQUE LED L21 HIGH IDLE LED L23 ENGINE STOP BN1 PIN10 O ENGINE START BN2 HIGH IDLE BN4 PIN19 HORN BN5 PIN23 HIGH TORQUE BN6 PIN24 O GENERATOR BN7 PIN25 O PIN29 O PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 PIN1 O LIFT ENABLE HIGH BN12 PIN2 O PIN3 PIN4 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 DIESEL MODELS WITH enie A TEREX COMPANY R15 JOYSTICK 26 9 5K CONTROLLER
27. MEME i PLATFORM CONTROLS BN MEMBRANE DECAL Elz Pour o POWER LED L19 l Pour o E LPG LED 122 5 5 5 5 555555 E POUT4 O lt lt 4 FAULT LED 125 2 9 POUTS o 4 GENERATOR LED 127 U5 2 8 Poure Ed qo HIGH TORQUE LED L21 ELECTRONIC CONTROL MODULE POUT8 4 HIGH IDLE LED L23 4 amp S F Fig 7 gt 0 gt 5 gt 8 amp amp 3 8 PS PIN5 4 4 ENGINE STOP BN1 PING e ENGINE START BN2 A 0 0 4 4 HIGH IDLE BN4 E PIN19 O 4 HORN BN5 EJ PIN 4 4 HIGH TORQUE BN6 LT 1 d 1 PIN24 O e GENERATOR BN7 X AL X X 2 PIN25 O ta PLATFORM EXT RET ENABLE BN16 PIN29 O ES 4 STARTING AID BN3 1 Mis 1 ES AI x fi X PIN13 4 4 LPG SELECT BN14 o e 4 LIFT ENABLE HIGH BN12 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Yi Y1A Y9 BL EN o v PIN2 LIFT ENABLE LOW BN13 do md E 32 nx X 2 2 2 2 52 m m B 2 lt lt lt lt lt 9 PINs 0 2 22 5 m TT T D X uw o9 A PLATFORM UP DOWN TS20 2 h 2 6 gt 3 gt OB O m m m E D D 2 gt 3 7 g n g 8 g 8 E E gt 429 gt gt gt ec r os POUT 8 8 R BR B B RB P 2 8 PIN11 ESSE POSITION WITH THE POWER OF
28. 5 90O e 9 a steer rocker switch SW6 b function enable high speed select button BN12 horn button BN 5 d platform extend retract enable BN16 OR outrigger enable button BN16 8 Turn the key switch to the off position to save the settings 9 Confirm the lift speed of the machine Refer to Section 2 Specifications Factory percentage settings Fast lift speed Gasoline LPG models 39 Diesel models 42 Part No 52302 July 2007 Section 4 Repair Procedures REV C How to Adjust the Slow Lift Speed 1 Remove the platform controls from the platform and place the controls near the diagnostic display at the ground control panel Turn the key switch to the off position Models without outriggers Press and hold the horn button and platform extend retract enable button then turn the key switch to platform controls Models with outriggers Press and hold the horn button and the outrigger enable button then turn the key switch to platform controls Result The diagnostic display window at the ground controls will show PS Note The PS showing in the diagnostic display window indicates that the ECM is in the programming mode 4 Release the horn button and the platform extend retract enable button or outrigger enable button Press and hold the function enable high speed select button to show the fast platform lift speed p
29. HIGH IDLE BN4 PIN19 HORN BN5 PIN23 HIGH TORQUE BN6 PIN24 O GENERATOR BN7 PIN25 O PIN29 O PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 PIN1 O LIFT ENABLE HIGH BN12 PIN2 O PIN3 PIN4 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 DIESEL MODELS WITH enie A TEREX COMPANY R15 JOYSTICK 26 9 5K CONTROLLER 8 WH BK WH YL sw5 FUNCTION ENABLE T pinis WHBL 2 4 I E e BK PLATFORM CONTROLS uM MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 i LIFT ERROR INDICATOR LED L57 POUT4 A 4 FAULT LED 125 POUTS 2 lt ES 4 GENERATOR LED L27 POUT6 O i HIGH TORQUE LED 121 POUT8 O 4 HIGH IDLE LED L23 L NT PIN5 O ENGINE STOP BN1 PING O e ENGINE START BN2 T PIN10 O 4 AUTO LEVEL BN20 E PIN19 O 4 HIGH TORQUE LF OUTRIGGER BN171 PIN23 22 4 HIGH IDLE BN4 PIN24 O RROUTRIGGER BN24 E OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 e PIN25 e
30. Crushing hazard The entry ladder AWARNING 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 AWARNING 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 AWARNING a platform down solenoid valve could become unbalanced and fall b upper lift cylinder if not properly supported when lower lift cylinder removed from the machine d pressure switch CE models Component damage hazard Be careful not to damage the valve or fittings on the cylinder while removing it from the machine 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 AWARNING Crushing hazard The lift cylinder will fall if not properly supported Genie 4 34 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV D 4 1 Timing Adjustment Complete information to perform
31. HIGH TORQUE BN6 ABTS fp PING 0 GENERATOR BN7 ABS AB15 8 d PN gt LPG SELECT BN14 Y36 Y34 Y40 Y44 T d o Vj rne 3 LF OUTRIGGER ENABLE BN85 Poo RF OUTRIGGER ENABLE BN86 A X X 2 M CQ Li BA PIN LR OUTRIGGER ENABLE BN87 Y35 Y33 Y39 RR OUTRIGGER ENABLE BN24 4 4 4 Be 8 x NR ge 5 E LIFT FUNCTION BN9 2 2 gt Db NAE 9 a 5 g S amp PIN14 O 4 ORGR AUTOLEVEL ENABLE BN20 3 3 3 8 B 2 E m 2 gt D 5 m m o o o PIN15 SYSTEM STATUS 150 2 gt m m m m m 2 4 mil 2 2 2 t m D po ud o 5 5 etd et rum im e m 9 J1 PIN4 X 5 m 2 3 2 PLATFORM UP DOWN TS20 E 2 2 gt BL OR o J1PIN3 O o 9 z 8 B N X PLATFORM 8 OUTRIGGER m m D UP DOWN m 2 2 0 80 T BK L E J1 PINS o RD H1 MACHINE SHOWN IN THE STOWED ici POSITION WITH THE POWER OFF ES7161D enie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 37 Section 6 Schematics July 2007 Electrical Schematic CE Models with Gasoline
32. 25 30 ft lbs 34 41 Nm 25 Solenoid valve 2 position 2 way Y aas Drive speed select circuit 25 30 ft lbs 34 41 Nm 26 Check valve Prevents overflowing the drive motors when in high drive speed 20 25 ft lbs 27 34 Nm 27 Check valve AA Prevents engine from running backwards when on an incline and reversing direction of travel 25 30 ft lbs 34 41 Nm 28 Counterbalance valve models with dynamic braking AB Improves braking performance 30 35 ft lbs 41 47 Nm 29 Counterbalance valve models with dynamic braking AC Improves braking performance 30 35 ft lbs 41 47 Nm Genie 4 74 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV D MANIFOLDS e Y ss Kel ae La DP eS or 25 amp xe d D 53 5 55 bt P gt m e i T lt gt Y9 9 c d P lt Su Genie Part No 52302 GS 2668 RT GS 3268 RT 4 75 Section 4 Repair Procedures July 2007 MANIFOLDS 9 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valves The function manifold contains two system relief valves one for each
33. 5 B ea DRIVE FORWARD cee ee rs ee ee z TUM J3 A2 N 8 BRAKE RELEASE z 95 S 2 2 5 gt K 5 lt DOWN 9 50 PLATFORM UP Oy p 2 PLATFORM 9 Q 99 ot ga E 1A H 3 X STEER LEFT i o Feit 5 thy 52 STEER RIGHT e 4 6 19 A TEREX COMPANY G 05 2668 RT 05 3268 RT Part No 52302 Section 6 Schematics July 2007 Electrical Schematic Gasoline LPG Models from serial number 38465 to 41199 Part 3 of 3 QD3 BK POWER TO PLATFORM A J A y RD POWER TO GROUND B l WH GROUND 0 D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS PRINTED CIRCUIT BOARD P2 EMERGENCY a STOP VOLTAGE REGULATOR BN R15 JOYSTICK gt 5K CONTROLLER 17 POTENTIOMETER 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE T RIGHT PIN18 WIUBE 4 BK PLATFORM CONTROLS A WH BRANE DECAL L19 LED 127 HIGH TORQUE LED L21 E p MEM POUT2 4 4 POWER LED POUT3 p2 POUT4 O 4 FAULT LED 125 POUTS ie ES 4 GENERATOR POUT6
34. AO t t t ON 1 C MODELS wi 2 1 DYNAMIC BRAKING gt i a Ox I hi Y1B 0 035 241 3 bar 0 89 mm Ww x a FT 200 psi i 13 8 bar e d Me 1M POEM E FUNCTION rc bar MANIFOLD SCHEDA Se RU DNE EESTI HS7044A HS0027P Genie Part No 52302 GS 2668 RT GS 3268 RT 6 109 Section 6 Schematics July 2007 EE This page intentionally left blank Genie 6 110 GS 2668 RT GS 3268 RT Part No 52302 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 49 422 149 1818 Fax 49 422 149 1820 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 U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55
35. B B WH GROUND C j C BK POWER TO PLATFORM yr A A RD POWER TO GROUND L REV B P2 EMERGENCY a STOP D D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS VOLTAGE REGULATOR PRINTED CIRCUIT BOARD REGULATOR BN R15 JOYSTICK gt 5K CONTROLLER POTENTIOMETER LPP 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE LERIZRIGHIT PIN18 WHEE 4 PLATFORM CONTROLS MEMBRANE DECAL POUT4 POWER LED L19 POUTS POUT6 29 FAULT LED 125 GENERATOR LED 127 PINS O 6 HIGH TORQUE LED L21 HIGH IDLE LED L23 ENGINE STOP BN1 PIN10 O ENGINE START BN2 HIGH IDLE BN4 PIN19 HORN BN5 PIN23 HIGH TORQUE BN6 PIN24 O GENERATOR BN7 PIN25 O PIN29 O PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 PIN1 O LIFT ENABLE HIGH BN12 PIN2 O PIN3 PIN4 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20
36. E Pod D 2 P m B f gd gt FF o m d o a 9 3 3 D 2 E 3S 5 9 5 3 7 gt 2 2 5 NOTE MACHINE SHOWN IN THE STOWED ES7183C POSITION WITH THE POWER OFF Genie A TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 47 Section 6 Schematics July 2007 Electrical Schematic CE Models with Gasoline LPG Power from serial number GS6805 44169 to GS6805 44770 Part 3 of 3 REVA CENE QD4 QD3 P2 EMERGENCY WHIRD 4 4 4 BK POWER PLATFORM STOP RD WH gt Rb POWER ro GROUND 31 BL 1 iH 1 1 WH GROUND 2 25 2 2 BL DATALINK HIGH OR 5 5 H 5 5 OR DATA LINK LOW jesse a 3 OUTRIGGERS OPTION J5 PIN2 2 gt eo PCS D7
37. LPG LED L22 HIGH IDLE LED 123 ENGINE STOP BN1 ENGINE START BN2 AUTO LEVEL BN20 HIGH TORQUE LF OUTRIGGER HIGH IDLE BN4 l LPG SELECT RR OUTRIGGER BN22 HORN LR OUTRIGGER BN15 GENERATOR RF OUTRIGGER BN18 OUTRIGGER ENABLE BN16 STARTING AID BN3 J BK POUT2 E 24 POUT3 Ed POUT4 La 5 POUT6 4 La POUT8 O l V 2 PIN5 8 PIN6 e PIN10 O s PIN19 PIN23 O 22 PIN24 O es T PIN13 O PIN25 O bu PIN25 O 4 me PIN29 O s Wn PIN2 BL ENABLE HIGH BN12 LIFT ENABLE LOW BN13 0 4 O POUT1 RD YE e p DOWN RD BK PIN11 H1 ALARM PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS PLATFORM amp OUTRIGGER UP DOWN TS21 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 21 July 2007 Section 6 Schematics Electrical Schematic REV D Gasoline LPG Models from serial number 41200 to 41823 Part 1 of 3 X START 1 J4 A2 J4 B6 J2 B8 o S GENERATOR OPTION N N lt 4 6 GENERA
38. 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 Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST A PROCEDURES 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 Genie GS 2668 RT GS 3268 RT REV A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whicheve
39. STOP C c L BK POWER TO PLATFORM A A RD POWER TO GROUND B B Lwa eroun opos opoz i D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE B B WH GROUND C j C BK POWER TO PLATFORM yr A A RD POWER TO GROUND L REV B P2 EMERGENCY a STOP D D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS VOLTAGE REGULATOR PRINTED CIRCUIT BOARD REGULATOR BN R15 JOYSTICK gt 5K CONTROLLER POTENTIOMETER LPP 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE LERIZRIGHIT PIN18 WHEE 4 PLATFORM CONTROLS MEMBRANE DECAL POUT4 POWER LED L19 POUTS POUT6 29 FAULT LED 125 GENERATOR LED 127 PINS O 6 HIGH TORQUE LED L21 HIGH IDLE LED L23 ENGINE STOP BN1 PIN10 O ENGINE START BN2 HIGH IDLE BN4 PIN19 HORN BN5 PIN23 HIGH TORQUE BN6 PIN24 O GENERATOR BN7 PIN25 O PIN29 O PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 PIN1 O LIFT ENABLE HIGH BN12 PIN2 O
40. g Ld Po o E p 4 4 r AUTOMOTIVE STYLE HORN E Stm X OPTION 8 8 i s js 8 moe ea N Cj HIGH IDLE SOLENOID j OW 62 00000 65 GLOW PLUG 21 0000012 4 7 4 4 4 mot O fb HOURMETER gT a 1 9 gos SU 8 5 E H d gt i LLI T O YH 6 FUEL SHUT OFF SS 8 OQ FUSE LLI 8 T 2 zu gt D ALTERNATOR ze a af E r A a a Ne lt X n e e i l 4 ENGINE STARTER N gt 2 ag 2 lt 5 J 2 que xess a I 9 55042 n ip BATTERY 12V DC D x Zag gt a ms 4 mE E m 6 58 Part 2 of 3 Section 6 Schematics Electrical Schematic Diesel Models from serial number 38465 to 40173 July 2007 REV B Au W zo pc J1 C7 C8 77 5 B IO 1 85 5 ul 2 a J2 B10 J2 A6 J2 C1 C10 4 z B YL DATAUINI CY YE 313 J2 B3 ou5 BK AUTO LEVELING Q z DATAUNK BK a4 18 2 0 SENSOR o RD elu Zz GROUND
41. O RIG O RIG J2PIN3 UMIT LIMT LIMT o lt o SWITCH SWITCH SWITCH SWITCH 5 E 9 SW5 1 S 5 J5 W6 gt gt NO NOS OR FUNCTION ENABLE 7 2 STEER 1 1 BK i X LEFT RIGHT 1 823 ABBA Qoo 2 a gt J2PIN7 AB27 AB26 16 Tasas fABT L J2PIN8 O 1 J2 PIN14 c c c c c c i oC C 7 9 m g g 8 2 2 8 8 POUTI PIN2 HORN BN5 U5 STARTING AID ELECTRONIC S a CONTROL PIN4 ENGINE START BN2 lt o 50 9 97 qm l i a o d PINs oes HIGH TORQUE BN6 ABTS fp PING 0 GENERATOR BN7 ABS AB15 8 d PN gt LPG SELECT BN14 Y36 Y34 Y40 Y44 T d o Vj rne 3 LF OUTRIGGER ENABLE BN85 Poo RF OUTRIGGER ENABLE BN86 A X X 2 M CQ Li BA PIN LR OUTRIGGER ENABLE BN87 Y35 Y33 Y39 RR OUTRIGGER ENABLE BN24 4 4 4 Be 8 x NR ge 5 E LIFT FUNCTION BN9 2 2 gt Db NAE 9 a 5 g S amp PIN14 O 4 ORGR AUTOLEVEL ENABLE BN20 3 3 3 8 B 2 E m 2 gt D 5 m m o o o PIN15 SYSTEM STATUS 150 2 gt m m m m m 2 4 mil 2
42. bz Li pe um NE BRNO LEFT REAR RIGHT REAR JC Tz gom OUTRIGGER OUTRIGGER 7 5 uM Op XU P2 m B Wi FUNCTION MANIFOLD e EI E 6 5 gpm 6 5 gpm 24 6 L min 24 6 L min 2 lt 9 lt 9 55 gt HYDRAULIC TANK HS0032D HS0027P Genio 6 108 GS 2668 GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Hydraulic Schematic REV B from serial number GS6804 43184 to GS6805 44770 Part 2 of 2 PLATFORM 9 35 ue RELEASE I OVERLOAD a ioa ENER MANIFOLD OPTION AK A DU mic uS 1 0 059 X 1 5 mm lt lt 7 lt 4 4 MN Eum c3 NN GS 3268 aL um di 9e i rci i X Y7A m baa ngA 1221 lesa J rr maj ma _ o O Y6A Ix ha Ee 121 EN HAM je MT ya 200 be e e DYNAMIC BRAKING 150058 200 psi
43. de c 125 05 ELECTRONIC CONTROL MODULE 5 5 S s T T 4 t 4 amp 5 5 OE gt 9 9 5 o zi 5 5 8 9 m S 9 22 ABI 7 1 Y4 Y1 Y1B Y6 Y6A Y9 Q2 Q1 E X 4 X 4 X EX X LY 7 2 S 7 T Sa L x EXP EX 0 4 M SW2 SW1 5 FB1 1 Y2 Y5 Y5A Y29 9 3 Se Ss gt o o gt w gm gt gt 9 m o E m E E 3 2 E 2 52 9 C 7 20 2 gt m m lt 2 2 lt 2 2 90 5 o m 9 lt v 7 m m rri lt lt f mi lt lt 8 fn 7 2 d 2 B m 2 m o 2 m m 2 m 2 gt y v D T OF gt 2 In z m 2 o gt gt m 2 lt m zd 34 m S oz o A J gt 2 2 mn m 2 lt o g 3 z S B Bs 2 RB 9 5 amp B 8 PF Rh gt e o m 9 5 2 2 5 B 9 9 x 5 3 o 9 2 E E 9 i NOTE MACHINE SHOWN IN THE STOWED ES7161A POSITION WITH THE POWER OFF Genie A TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 31 Section 6 Schematics July 2007 Electrical Schematic ANSI Models with Gasoline LPG Power from serial number GS6803 42382 to GS6805 43594 Part 3 of 3 REVA
44. m lt 2 lt 2 2 2 zz mz mo mo m m m m m o m I c m gt m gt DA 22 m DD D m 2 d e gt gt gt gt 2 ZS m 2 m z m m o m m m m m mer m o m 2 m 9 6 8 6 4 MACHINE SHOWN IN THE STOWED ES0116U POSITION WITH THE POWER OFF enie A TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 23 Section 6 Schematics July 2007 Electrical Schematic Gasoline LPG Models from serial number 41200 to 41823 Part 3 of 3 QD3 BK POWER TO PLATFORM A J A y RD POWER TO GROUND B l WH GROUND 0 D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS PRINTED CIRCUIT BOARD P2 EMERGENCY a STOP VOLTAGE REGULATOR BN R15 JOYSTICK gt 5K CONTROLLER 17 POTENTIOMETER 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE T RIGHT PIN18 WIUBE 4 BK PLATFORM CONTROLS A WH BRANE DECAL L19 LED 127 HIGH TORQUE LED L21 E p MEM POUT2 4 4 POWER LED POUT3 p2 POUT4 O 4 FAULT LED 125 POUTS ie ES 4 GENERATOR POUT6 e 06 1 POUT7 O D 4 E 4 LPG LED L22 POUT8 O HIGH IDLE LED 123 PINS a ENGINE STOP B
45. o 50 9 97 qm l i a o d PINs oes HIGH TORQUE BN6 ABTS fp PING 0 GENERATOR BN7 ABS AB15 8 d PN gt LPG SELECT BN14 Y36 Y34 Y40 Y44 T d o Vj rne 3 LF OUTRIGGER ENABLE BN85 Poo RF OUTRIGGER ENABLE BN86 A X X 2 M CQ Li BA PIN LR OUTRIGGER ENABLE BN87 Y35 Y33 Y39 RR OUTRIGGER ENABLE BN24 4 4 4 Be 8 x NR ge 5 E LIFT FUNCTION BN9 2 2 gt Db NAE 9 a 5 g S amp PIN14 O 4 ORGR AUTOLEVEL ENABLE BN20 3 3 3 8 B 2 E m 2 gt D 5 m m o o o PIN15 SYSTEM STATUS 150 2 gt m m m m m 2 4 mil 2 2 2 t m D po ud o 5 5 etd et rum im e m 9 J1 PIN4 X 5 m 2 3 2 PLATFORM UP DOWN TS20 E 2 2 gt BL OR o J1PIN3 O o 9 z 8 B N X PLATFORM 8 OUTRIGGER m m D UP DOWN m 2 2 0 80 T BK L E J1 PINS o RD H1 MACHINE SHOWN IN THE STOWED ici POSITION WITH THE POWER OFF ESTIGA enie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 89 Section 6
46. uu 5 amp x x gi Zw 8 8 8 5 n PIN13 O LIFT FUNCTION BN9 m m o CN OL 2 25 o 9 S x PIN14 ORGR AUTOLEVEL ENABLE BN20 i 4 i 4 E X o 35 1 2 f 5 a m o o o m PIN15 O SYSTEM STATUS L50 z 2 m m m m m a 2 2 2 2 g m 2 1 R 5 7 o menmie 8 m 9 0 1 S E E 5 gt 5 2 fu PLATFORM UP DOWN TS20 8 Q o 5 o EJ J1 PIN OR g O m 4 5 PLATFORM amp OUTRIGGER m m UP DOWN J 7 m z 0 90 dr L 4 Ji PINS o rS I MACHINE SHOWN IN THE STOWED pL ND PLATFORM POSITION WITH THE POWER OFF CONTROLS ES7183C enie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 49 July 2007 REV B Part No 52302 Genie GS 2668 RT GS 3268 RT ATE Diesel Models before serial number 21161 Electrical Schematic Part 1 of 2 Section 6 Schematics gt lt zp 5 oy E J4 A4 gt lt o Og HI
47. 9 m o E m E E 3 2 E 2 52 9 C 7 20 2 gt m m lt 2 2 lt 2 2 90 5 o m 9 lt v 7 m m rri lt lt f mi lt lt 8 fn 7 2 d 2 B m 2 m o 2 m m 2 m 2 gt y v D T OF gt 2 In z m 2 o gt gt m 2 lt m zd 34 m S oz o A J gt 2 2 mn m 2 lt o g 3 z S B Bs 2 RB 9 5 amp B 8 PF Rh gt o v 6 o m 9 5 2 2 5 B 9 9 i 5 3 o 9 2 E E 9 i NOTE MACHINE SHOWN IN THE STOWED ES7161D POSITION WITH THE POWER OFF Genie A TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 35 Section 6 Schematics July 2007 Electrical Schematic ANSI Models with Gasoline LPG Power from serial number GS6805 43595 to GS6805 44770 Part 3 of 3 REVA QD4 QD3 P2 Q EMERGENCY
48. 944 NEUE D P 30 86 1 77 CR17 HYDRAULIC OIL COOLE OPTION BATTERY AL 30 ABZ 7 LEVEL SENSOR CIRCUIT BOARD PES OUTRIGGERS 2 4 M1 I LEVEL 57 SENSOR MODELS WITHOUT 29 rs c U5 S ELECTRONIC CONTROL MODULE S 5 5 S f t F amp amp n a gt gt gt 1 a a I y o 5 8 E 9 AB22 4 4 Y4 X1 Y1B Y6 Y6A Y9 A 2 X 4 4 n n n gt Jt C kd x X X A X X CX Sw2 SW1 H5 FB1 Y1A Y2 Y5 Y5A Y29 4 4 4 4 2 4 4 n o I lt lt lt lt lt M lt lt lt lt lt lt m a w gt a a e z E 3 2 9 Z3 o 5 o o 2 2 2 8 gt 5 m B 5 2 x 2 3 99 D 3 5 8 2 3 9 9 amp A A 5 s 54 4 8 m 2 5 y 2 Z SG m OF 5 5 lul 9 2 D 2 2 2 lt m zz o z a gt 2 m z m 2 lt o S d 4 5S 2 R g Bl 5 Ph Rh mM 5 B 5 mg 8 o m m D 2 2 7
49. 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 Part No 52302 Genie GS 2668 RT GS 3268 RT 3 1 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 AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided m
50. from serial number GS6805 44169 to GS6805 44770 Part 1 of 3 FQsaruse P1emercency IKS1 SwitcH T Bi gt EE CONTROL 4 T P S 2A PLATFORM OVERLOAD PRESSURE SWITCH gt B R25 3 5 OHM NN GROUND CONTROL pii 2 CB2 20a 7 e aBa T AB28 CR41 1 CR23 G6 N C CONTROL CR42 CR5 CR8 ENGINE AUXILIARY HOUR 1 SYSTEM POWER HORN IGNITION START DOWN 27 Su LS6 PLAT 86 86 86 a 86 4 86 86 s i DOWN 0 2 0 o EK EK LIMIT 85 85 8 e 85 85 85 SWITCH AB2i 7 US EM 2 8 8 a 31 07 BN23 BN91 J2 C4 0 AUXILIARYDOWN AUXILIARY DOWN AS ENABLE U19 p J2B9 8 5 CR
51. 2 2228 5 8 5 amp 5o 23 8 IR 8 8 52685 1 D 9 lt 58 2 AXIS LEVEL SENSOR eX X cox cx 1 1 1 X X X X CCP 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Yi YIA Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9 o v w g g mo o gt E 2 m 2 3 2653 jg ga g 58 5 g m f m m m m m m m z g 25 25 2 2 22 8 D D D D o D gt p 2 g 9 gt gt BZ OB OF Om o m o J m lt 2 lt J 2 J 2 mz mo my m m m m m T m gt gt gt gt 24 22 D DD D D D E m 2 2 E 22 6 8 5 D m h 92 E m E 5 8 m m ps ca a x m 2 gt 2 E 4 ES7140C POSITION WITH THE POWER OFF enie Part No 52302 GS 2668 RT GS 3268 RT A TEREX COMPANY Section 6 Schematics July 2007 Electrical Schematic Diesel Models from serial number 21838 to 38464 Part 3 of 3 P2 EMERGENCY STOP C c L BK POWER TO PLATFORM A A RD POWER TO GROUND B B Lwa eroun opos opoz i D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE
52. 3 5 Genie GS 2668 RT GS 3268 RT vii July 2007 TABLE CONTENTS Section 3 Rev Scheduled Maintenance Procedures continued C Checklist A Procedures A 1 Inspect the Manuals and 3 7 2 Perform Pre operation 3 8 Perform Function 4044 3 8 4 Perform Engine 3 9 5 Inspect the Engine Air 3 9 6 Perform 30 Day 3 10 A 7 Perform Engine Maintenance Kubota D905 Models 3 11 8 Perform Engine Maintenance Kubota Models 3 11 A 8 Perform Engine Maintenance Kubota Models 3 12 A 9 Perform Engine Maintenance Kubota Models 3 12 A 11 Drain the Fuel Filter Water Separator Diesel Models 3 13 A 11 Perform Engine Maintenance Kubota D905 Models 3 14 D Checklist B Procedures B 1 Inspect the Battery 3 15 B 2 Inspect the Electrical 3 16 B 3 Inspect the Tires Wheels and Lug Bolt Torque 3 17 B 4 Perform Engine Maintenance Perkins 403C 11 Models 3 17 B 5 Test the Key 3 18 B 6
53. 38 gt gt gt f r o os POUT 8 8 R BR B B m P PIN11 ES7140A POSITION WITH THE POWER OFF enie Part No 52302 A TEREX COMPANY GS 2668 RT GS 3268 RT STOP 2007 REV B P1 EMERGENCY PLATFORM KS1 Diesel Models from serial number 21161 to 21837 Electrical Schematic Part 1 of 2 Section 6 Schematics x l B D Q E J4 A4 px o m HIGH IDLE 2 N GENERATOR OPTION 5 b A 2 5 Sj GENERATOR ON LED WA E ppal Ne OIL PRESSURE LED GLOW PLUG DE g Si e 2 8 PI Ne COOLANT lt 0 3 5 X TEMPERATURE LED a START E J4 B2 amp OIL PRESSURE SWITCH o E 4245 2 He COOLANT od TEMPERATURE SWITCH J4 B5 m 315011012 O FLASHING BEACON OPTION A z e m 3 pea J2 I TILT ALARM J4 C3 1 lt PLATFORM DOWN PIS gt 95 3268 ONLY z 2 u 11 42 PLATFORM DOWN gg 2 e Pea e z a 5 cy 53 8 8 B11 1 J1
54. 5 5 8 9 m S 9 22 ABT ABI 7 1 4 4 Y4 Y1 Y1B Y6 Y6A Y9 Q2 Q1 2 X X X LY d 4 4 4 4 l p We cf Xi 08 Sw2 SW1 H5 FB1 1 Y2 Y5 Y5A Y29 4 4 4 4 4 4 4 4 4 2 g g 5 o5 3 48 2 amp E B B2 2 a 5 d 8 3 8 9 9 9 2 5 9 gt m m 2 2 3 gt 2 2 3 m 5 m o lt v 8 E m Z2 m 2 29 Z p 28 2 2 BF m 2 m 2 gt y v D T OF gt 2 In z m 4 o o 2 2 gt m 2 lt m zd 34 m S5 2 o A J gt 2 2 mn m 2 lt o S 9 g Z B gt fl m z 5 PF h m mn n 5 8 F m 2 m o a 3 9 5 4 5 3 ov 9 8 9 5 3 o Z 9 NOTE MACHINE SHOWN IN THE STOWED eee POSITION WITH THE POWER OFF Genie Part No 52302 A TEREX COMPANY GS 2668 RT GS 3268 RT Section 6 Schematics July 2007 Electrical Schematic CE Models with Gasoline LPG Power REV B from serial number GS6805 43595 to GS6805 44168 Part 3 of 3
55. 2 Push down the horn button at the platform controls Result The horn should sound If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn Genie Part No 52302 GS 2668 RT GS 3268 RT 3 19 Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST B PROCEDURES 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 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 Qo REV D Press the high idle button again to return the engine to low idle Result The
56. 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 Section 4 Repair Procedures July 2007 Perkins 403C 11 Engine 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 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 Movethe 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
57. 7 I ESL CO 1 e wp LEES mom 1 Loewe ELLE me won pe tet 1 I i ns ELLE 0000107 LLL 0001007 LEE Lb efor 125 LEES xr mro LEE re e p lil e Low pese p 1 e poor EDI wr muro pp 7 88 pono EDS Low pese p Ii 00866 Lom pese we pb Lopes 143 00111001 191101101111 Genie Part No 52302 GS 2668 RT GS 3268 RT A 21 Co Section 4 Repair Procedures July 2007 Platform Components 2 1 Platform How to Remove the Platform AWARNING 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 comp
58. E PLATFORM KS1 7A LPG SELECT 7 TS3 TS54 HIGH IDLE CHOKE 556 552 START _ xn CR43 POWER TO ECM CR25 ENGINE RUN 30 CR8 IGNITION CR15 STARTING 4 HIGH IDLE 85 86 85 86 87 m 85 86 85 186 30 L7 85 86 87 J4 A4 J4 A3 1 J4 A2 J2 A5 J4 A5 ELECTRONIC CONTROL MODULE J4 B5 J1 C11 C12 J4 C4 J4 C3 J4 B4 J4 C2 J4 C1 J4 B6 J2 B8 J2 B7 9 8 GASOLINE SELECT X FUEL PUMP Q2 X PX Q1 EN LPG SELECT OX 81 GENERATOR OPTION N Le N S GENERATOR ON LED X gt L42 3 OIL PRESSURE LED COOLANT J4 B2 J4 B1 is zi 6 N C ES TEMPERATURE LED L 0 OIL PRESSURE SWITCH COOLANT J2 B12 SW1 B N O S TEMPERATUR E SWITCH 1 TILT ALARM J2 B11 Mo tis ea 1 J1 C1 C4 J1 A9 H O e FLASHING BEACON OPTION 5 AUXILLIARY PLATFORM DOWN 4 95 3268 ONLY lt PLATFORM DOWN 54 GS 3268 ONLY o AUXILLIARY PLATFORM DOWN 86 te SE 85 x 5 PLATFORM DOWN
59. lockout RD Red BN6 High torque Q2 Gasoline lockout WH White BN7 Generator Q3 High idle YL Yellow BN11 Driving lights Q8 Fuel shut off BL RD Blue R ed BN12 High speed lit enable QD Quick disconnect BL WH Blue White BN13 Low speed lift enable BN15 Horn left front outri QD3 Control cable to ground BK RD Black Red norniert tront outrigger QD4 Control cable to platform OR WH Orange White BN16 Outrigger function enable R Resistor RD BK Red Black BN17 High torque left front outrigger 7000 RDIWH RediWhit BN18 Generator right front outrigger R7 Q resistor BN20 Outrigger auto level R15 0 to 5000 ohm potentiometer WH BL White Blue BN22 Right rear outrigger S Sensor WH BK White Black BN23 Auxiliary platform down 57 Tilt sensor models without outriggers WH RD White Red C2 Capacitor 33000 uf S8 Tilt sensor models with outriggers WH YL White Y ellow CB Circuit breaker SW Switch YL BK Yellow Black 20 amp SW1 Engine coolant temperature CB2 1 before serial number 24000 SW2 Engine oil pressure CB2 7 amp after serial number 23999 5 5 lt Function enable CR Control relay SW6 Steer left right Engine start SW25 DIP switch CR4 High idle TS Toggle switch CR5 Horn relay T56 Glow plug CR8 Ignition 1520 lt Platform up down CR15 Glow plug 521 Platform up down amp outrigger CR17 Hydraulic oil cooling fan extend retract CR25 Engine run Engne CR34 Dr
60. 7 Rb POWER ro GROUND 2 31 BL 1 1 1 1 WH GROUND BK r 2 2 2 2 BL DATALINK HIGH OR 5 5 1 1 5 5 5 1 OR DATA LINK LOW 1 OUTRIGGERS OPTION J5 PIN2 2 D7 PLATFORM CONTROLS VOLTAGE cipio PRINTED CIRCUIT BOARD REGULATOR S8 2 TILT LEVEL J2 PIN1 SENSOR a YL HALL EFFECT 9 7 ERATOE JC1 9 I 9 42 PIN12 JOYSTICK 1812 1813 1814 1815 4 8 e CONTROLLER n0 9 J2PIN13 O LF RF LR RR m O RIG O RIG J2PIN3 UMIT LIMT LIMT o lt o SWITCH SWITCH SWITCH SWITCH 5 E 9 SW5 1 S 5 J5 W6 gt gt NO NOS OR FUNCTION ENABLE 7 2 STEER 1 1 BK i X LEFT RIGHT 1 823 ABBA Qoo 2 a gt J2PIN7 AB27 AB26 16 Tasas fABT L J2PIN8 O 1 J2 PIN14 c c c c c c i oC C 7 9 m g g 8 2 2 8 8 POUTI PIN2 HORN BN5 U5 STARTING AID ELECTRONIC S a CONTROL PIN4 ENGINE START BN2 lt o 50 9 97 qm l i a o d PINs oes HIGH TORQUE BN6 ABTS fp PING 0 GENERATOR BN7 ABS AB15
61. BRNO LEFT REAR RIGHT REAR JC Tz gom OUTRIGGER OUTRIGGER 7 5 Se EX P2 m B Wi FUNCTION 2935 MANIFOLD e e E 6 5 gpm 6 5 gpm 24 6 L min 24 6 L min THE Oban 1 7 bar 1 o HYDRAULIC TANK HS0032D HS0027L Genio 6 106 GS 2668 GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Hydraulic Schematic REV B from serial number GS6803 42380 to GS6804 43183 Part 2 of 2 PLATFORM SENS ID OVERLOAD A lasam ONES MANIFOLD OPTION AK Eu d 3 L Y7 Y10 Doe MS GS 3268 1 SSS ura Ho XQ a Y7A ay O INI Eus ou 22 22 7 Y6A X 2 49 i ES LJ 4 LA p W Boss e DYNAMIC BRAKING 4600 pal p T T T umm Due B a Ox I hi Y1B 0 035 241 3 bar 0 89 mm Ww x 200 psi 13
62. E 058 eH E 0 8 l gt lt i 1 J1 A10 DRIVE PARALLEL Lo enl ntum aun J1 A8 1 7 12 DRIVE REVERSE zi uad pa 04 5 2 Nox zi ut a7 DRIVE FORWARD 4 gt 1 E S J3 A1 E d J1 A6 2 DRIVE REVERSE 5 9 Zi 5 i Jt A5 DRIVE FORWARD b gt _______ l 1 EL J9 2 Q _ BRAKE RELEASE E 28 z 2 e z DOWN t 9 PLATFORM UP p mea PLATFORM 9 ot P J1 A2 Hr X STEER LEFT o Fea a 52 STEER RIGHT 07 4 6 63 A TEREX COMPANY G 05 2668 RT 05 3268 RT Part No 52302 Section 6 Schematics July 2007 Electrical Schematic Diesel Models from serial number 40174 to 40939 Part 3 of 3 P2 EMERGENCY STOP C c L BK POWER TO PLATFORM A A RD POWER TO GROUND B B Lwa eroun opos opoz i D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE B B WH GROUND C j C BK POWER TO PLATFORM yr A A RD POWER TO GROUND L REV B P2 EMERGENCY a STOP
63. FAULT LED 125 GENERATOR LED 127 PINS O 6 HIGH TORQUE LED L21 HIGH IDLE LED L23 ENGINE STOP BN1 PIN10 O ENGINE START BN2 HIGH IDLE BN4 PIN19 HORN BN5 PIN23 HIGH TORQUE BN6 PIN24 O GENERATOR BN7 PIN25 O PIN29 O PLATFORM EXT RET ENABLE BN16 STARTING AID BN3 PIN1 O LIFT ENABLE HIGH BN12 PIN2 O PIN3 PIN4 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 DIESEL MODELS WITH enie A TEREX COMPANY R15 JOYSTICK 26 9 5K CONTROLLER 8 WH BK WH YL sw5 FUNCTION ENABLE T pinis WHBL 2 4 I E e BK PLATFORM CONTROLS uM MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 i LIFT ERROR INDICATOR LED L57 POUT4 A 4 FAULT LED 125 POUTS 2 lt ES 4 GENERATOR LED L27 POUT6 O i HIGH TORQUE LED 121 POUT8 O 4 HIGH IDLE LED L23 L NT PIN5 O ENGINE STOP BN1 PING O e ENGINE START BN2 T PIN10 O 4 AUTO LEVEL BN20 E PIN19 O 4 HIGH TORQUE LF OUTRIGGER BN171 PIN23 22 4
64. FLASHING BEACON OPTION J4 B5 E MA e J1 C11 C12 sea TILT ALARM 5 E 4 AUXILIARY PLATFORM QNS e J4 C4 ak DOWN 05 3268 ONLY 3 J4 c3 9 lt PLATFORM DOWN n 5 05 3268 ONLY z c QAAE ox MI 8 AUXILIARY PLATFORM 5 Y DOWN GS 3268 ONLY c gt o uj 925 a PLATFORM DOWN uu _ e mea amp 8 658 jes Fi OG Or 3 8 2 11 2 a 8 8 8 8 d ir ir m ic 4 i r AUTOMOTIVE STYLE HORN als Suri a wt BNE OPTION 9 e e 9 09 8 WORK LIGHTS OPTION a 8 N HIGH IDLE SOLENOID S OW 00000 6 GLOW PLUG 00000 4 1 4 4 Of HOURMETER M d i 9 15 LL 4 4 Sl S Or 1 1 O amp FUEL SHUT OFF pa o o LLI 8 aw im FUSE 2 D ALTERNATOR ze g C os nas a 5 5 Kis BE 4 z o e 2 2 N gt ENGINE STARTER z RN gt m E 9 z5 ee J 2 E 545 8s BATTERY 12V DC L lt 4209 i gt lan 52 1 52302 Genie GS 2668 RT GS 3268 RT ATE 6 62 Part 2 of 3
65. GS 2668 RT GS 3268 RT Part No 52302 6 74 July 2007 Section 6 Schematics Electrical Schematic REV Diesel Models from serial number 41824 to GS6803 42381 Part 2 of 3 P1 EMERGENCY 004 i B B D D zn G8 OUTRIGGERS DIAGNOSTIC OPTION OPTION DISPLAY BN44 FUNCTION ENABLE ge Ss LS6 PS3 PLATFORM PLATFORM ELI 1512 LS13 1614 1815 0 TS54 BN83 BN84 E LEFT RIGHT LEFT RIGHT GLOW HIGH PLATFORM PLATFORM o FRONT FRONT REAR REAR PLUG IDLE 7 UP DOWN NC 4 NO OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER 1 T HE 9 T ew c 118 1 1 rls 2 J i 2 MODELS AJS WITHOUT LEVEL E gt gt OUTRIGGERS SENSOR OU ERE 2 T BN c c c a lt c 1 Dy 55 o PHN amp x 5 x 5 a ere 295 U5 Q e S a ELECTRONIC CONTROL MODULE 7 l lt s s s s amp amp F 20 1 05 t BES gt 0 gt 5 S 2228 5 t amp 5 5 amp 5o 5 8 8 8
66. GS 3268 RT Genio cha REV B 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 Ibs 6 1 Nm Note Clean the fuel tank and inspect for cracks or other damage before installing Part No 52302 July 2007 Section 4 Repair Procedures REV B 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 Two Hydraulic Hose and Fitting Torque Specifications 1 Raise the platform approximately 10 feet 3 m 2 Liftthe safety arm move it to the center of the scissor arm and rotate
67. Genie bebe CHECKLIST D PROCEDURES Apply a thin layer of fresh oil to the new oil filter gasket Install the new filter and tighten it securely by hand Use a permanent ink marker to write the date and number of hours from the hour meter on the filter Clean up any oil that may have spilled during the replacement procedure 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 Raise the platform approximately feet 1 m Inspect the filter and related components to be sure that there are no leaks GS 2668 RT GS 3268 RT 3 31 Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST D PROCEDURES D 3 Perform Engine Maintenance Perkins 403C 11 Models Engine specifications require that this procedure be performed every 1000 hours Required maintenance procedures and additional engine information is available in the Perkins 403C 11 User s Handbook Perkins part number 100816460 Perkins 403C 11 User s Handbook Genie part number 97360 REV D 4 Perform Engine Maintenance Kubota DF752 Models Engine specifications require that this procedure be performed every 1000 hours Required maintenance procedures and additional engine information is available in the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota DF752 Operator s Manual Genie p
68. HYDRAULIC OIL 0 TEMPERATURE SWITCH OPTION 9 15 4 7 M1 HYDRAULIC OIL COOLER p GROUND GROUND V DC amp L vili Fur PS M U19 U26 020 HYDRAULIC OIL COOLING FAN OPTION SPARK PLUG S DISTRIBUTOR IGNITION COIL Cy ALTERNATOR CB1 20A 2 3 ENGINE STARTER ul HE E saren ES0116U nin tt mi E zm zi I SE Ls 7 zo oQ9o enie COMPANY GS 2668 RT GS 3268 RT ATE Part No 52302 6 22 July 2007 Section 6 Schematics Electrical Schematic REV D Gasoline LPG Models from serial number 41200 to 41823 Part 2 of 3 P1 EMERGENCY M M stor QD4 Tw as D D a E E 1 G8 BH OUTRIGGERS DIAGNOSTIC OPTION OPTION DISPLAY e BN44 FUNCTION ENABLE LS6 PS3 f PLATFORM PLATFORM PT oe 1512
69. 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 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 no remove from service R repaired Checklist A Rev C Y NR Checklist B Rev D A 1 Manuals and decals B 1 Battery 2 Pre operation inspect B 2 Electrical wiring A 3 Function tests B 3 Tires and wheels 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 D905 models Perform every 50 hours A 8 Engine maintenance Kubota models Perform every 100 hours B 4 Engine maintenance Perkins 403C mode
70. Refer to Section 2 Specifications Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS 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 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 Section 4 Repair Procedures July 2007 GROUND CONTROLS How to Adjust the Raised Drive Speed ADANGER 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 Note On machines with software revision B1 or lower raised drive speeds in forward and reverse are simultaneously adjusted resulting in both directions of
71. Schematics July 2007 Electrical Schematic CE Models with Diesel Power REV B from serial number GS6805 43595 to GS6805 44168 Part 1 of 3 F9 sa rusE P1emercency stop KS1 KEYSWITCH d E e e B1 PLATFORM CONTROL ts 4141 m PS2A PLATFORM OVERLOAD PRESSURE SWITCH PR eee GROUND CONTROL AB20 C CB2 20a 1 28 CR41 CRI CR23 G6 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY HORN IGNITION START DOWN O4 E 156 PLAT 86 2 86 2 86 A 86 al 4 86 86 2 DOWN ij ES ib LIMIT 85 ef 85 85 85 pu 85 85 871 SWITCH 4 1 US EM 2 amp 8 8 y E uer e eec EXCT J1 C7 BN23 BN91 A J2 C4 0 lt D
72. enie A TEREX COMPANY Serial Number Range GS 2668 RT 65 3268 RT Part 52302 Rev F July 2007 July 2007 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Technical Publications Genie Industries has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www genieindustries com e mail techsup genieind com Genio Copyright 1998 by Genie Industries 52302 Rev F July 2007 First Edition Sixth Printing Genie is a registered trademark of Genie Industries in the USA and many other countries GS is a trademark of Genie Industries 4 Pr
73. 1512 LS13 1614 1815 BN90 T854 BN83 BN84 E LEFT RIGHT LEFT RIGHT GLOW HIGH PLATFORM PLATFORM o FRONT FRONT REAR REAR PLUG IDLE 7 UP DOWN NC 4 NO OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER 1 See ME o o 8 1 1 1 EE 2 J i 2 MODELS AJS WITHOUT LEVEL 5 OUTRIGGERS SENSOR a T BN D m m c c a lt c c cur Mies c 1 E N N ooo 5 YNNN amp x 5 pim amp 5 968 Q amp Q U5 x 575 g 1 2 T n ELECTRONIC CONTROL MODULE x s s 55 525755 t BES gt gt 3 i d 2228 5 t amp 5 5 amp 5o 5 8 8 8 1 iD lt p S8 2 AXIS LEVEL SENSOR ig X X 45 oX kX X X AX 54 94 m A ET e Y4 8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9 o OD o o oo n gt 4 2 2 5 2 2 2 5 2 2 2 13 38 2 28 3 25 25 5 T f m m m m m m m 5 2 25 25 2 2 2D RO o T 2 T 2 2 2 o9 OD Og o o 9E 2 m 2 a o m 2 2 gt OF OL Om o o m o J 2 lt 2 lt 2 2 2 zz mz mo
74. 2 lt OIL PRESSURE SWITCH SAS 2 E COOLANT J2 A5 2 m 1 3 TEMPERATURE SWITCH J4 A5 _ J1 B1 C gt 0 FLASHING BEACON OPTION J4 B5 J1 C11 C12 J2 B12 Ir TILT ALARM 5 AUXILIARY PLATFORM T DOWN GS 3268 ONLY J4 C4 lt PLATFORM DOWN 95 3268 ONLY J4 C3 J4 B4 J4 C1 C4 AUXILIARY PLATFORM T gt DOWN GS 3268 ONLY 4 Dx gt PLATFORM DOWN e J1 A9 CR43 POWER TO ECM CR25 ENGINE RUN CR8 IGNITION STARTING AID 2 Es CR15 CR4 30 HIGH IDLE 30 5 1 86 EN E CR5 86 30 1 8 30 AUTOMOTIVE STYLE HORN S 5 T OPTION 8 WORK LIGHTS OPTION 87 4 2 85 86 Tera 85 86 L30 8 HIGH IDLE SOLENOID 85 87 m 85 87 5 CHOKE HOURMETER UN CR1 ENGINE START 87 E z 4 52 g 1 8 HYDRAULIC OIL 2 18 TEMPERATURE SWITCH HYDRAULIC OIL 2 COOLING FAN OPTION HYDRAULIC OIL COOLER OPTION M1 SPARK PLUG S DISTRIBUTOR 2 4 3 019 U26 U20 IGNITION CO
75. 20 Install the platform controls into the platform and connect the platform controls to the quick disconnect plug at the bottom of the platform Genie Part No 52302 GS 2668 RT GS 3268 RT 4 81 Section 4 Repair Procedures July 2007 MANIFOLDS REV D 9 5 Generator Manifold Components The generator manifold is located above the function manifold Index Schematic No Description Item Function Torque 1 Solenoid valve 2 position 3 way DA us Generator 25 ft lbs 34 Nm 2 Flow regulator 4 3 16 3 L min DB Generator speed 20 ft lbs 27 1 Nm 3 Relief valve 3000 psi 206 8 bar DC Generator 20 ft lbs 27 1 Nm e Genie 4 82 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV D 9 6 Valve Adjustments Generator Manifold How to Adjust the Generator Voltage AWARNING ird injury hazard Spraying ydraulic 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 AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Be sure that
76. 3 6 m Result ANSI and CSA models The tilt alarm will sound at 180 beeps per minute O Result CE and Australian models The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute After serial number 41136 Raise the platform at least 12 feet 3 6 m Result The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute If you are not installing a new level sensor proceed to step 21 9 Push in the red Emergency Stop button to the off position at the platform controls Before serial number 41200 10 Remove the ground control panel retaining fasteners and open the panel Locate the level sensor behind the ground control panel After serial number 41199 11 Lift the safety arm move to the center of the scissor arm and rotate to a vertical position 12 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Section 4 Repair Procedures July 2007 GROUND CONTROLS REV D 13 Locate the level sensor enclosure on the chassis under the limit switches at the steer end of the machine Remove the enclosure cover retaining fasteners and the cover MODELS WITHOUT OUTRIGGERS L E BEFORE eo SERIA pe ul E Level sensor models without
77. 57044 50027 Genio Part No 52302 GS 2668 RT GS 3268 RT 6 103 Section 6 Schematics July 2007 S Hydraulic Schematic HYDRAULIC TANK from serial number 40485 to GS6803 42379 REV B Part 1 of 2 5 GENERATOR OPTION r 691 GENERATOR OUTRIGGERS MANIFOLD OPTION zl 08 45 LEFT FRONT RIGHT FRONT L __ 3000 psi 17 OUTRIGGER OUTRIGGER oem sti He xe RL OO oh MN e STEER CYLINDER T __ __ __ SD e LEFT RIGHT t 2 1 s2 n x lt lt gt Semm E JK 1 Ya J 7 TI Y40 IIH d Y39 R WA 1 Y E OUTRIGGER 3 69 11 9 x MANIFOLD gt 1 L4 37 EX uu 137 8 bar OUT C 1500 psi Li 1084 bar F Loo p o LA _ LEFT REAR RIGHT REAR Tz OUTRIGGE
78. A10 of the terminal strip to terminal B9 of the terminal strip 9 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 10 Fully raise the platform Release the joystick O 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 Part No 52302 July 2007 Section Scheduled Maintenance Procedures REV 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 O Result The platform should stop raising at maximum height The engine should continue t
79. ANSI and CSA models The tilt alarm sounds at 180 beeps per minute Proceed to step 42 Result CE and Australian models The drive function and the lift function will not operate and the tilt alarm sounds at 180 beeps per minute Proceed to step 42 After serial number 41136 Raise the platform at least 12 feet 3 6 m O Result The tilt alarm does not sound and all functions will operate Proceed to step 43 Result The drive function and the lift function will not operate and the tilt alarm sounds at 180 beeps per minute Proceed to step 42 Genie GS 2668 RT GS 3268 RT REV D 42 Turn the level sensor adjusting nuts just until the level sensor alarm does not sound 43 Lower the platform to the stowed position 44 Raise the machine slightly 45 Remove the blocks from under both wheels 46 Lower the machine and remove the jack 47 Center a lifting jack under the drive chassis at the engine side of the machine 48 Raise the machine approximately 4 inches 10 cm 49 Models with RT tires Place a 2 15 x 10 x 10 inch 5 46 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine All other models Place a 2 25 x 10 x 10 inch 5 72 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine 50 Lower the machine onto the blocks Part No 52302 July 2007 Section 4 Repair Procedures REV D 51 Before serial number 4113
80. Always wear approved steel toed shoes Genio vi GS 2668 RT GS 3268 RT Part No 52302 July 2007 Introduction Section 1 Section 2 Rev D Section 3 Rev Table of Contents Important certe li Serial Nuiriber Legend iii Safety Rules General Safety Rules esses nennen nnne V Specifications Machine 2 1 Performance 2 2 Hydraulic Specifications 2 2 Manifold Component 2 3 Kubota D905 2 4 Kubota D905 Tier 2 Engine 2 5 Perkins 409C 11 Engine odictor 2 6 kupola DESO Englrie 2 oerte meter ec ntt as 2 7 Kubota DF752 Engine 2 8 Hydraulic Hose and Fitting Torque Specifications 2 9 SAE and Metric Fasteners Torque 2 10 Scheduled Maintenance Procedures Part No 52302 CUNO ect 3 1 Pre delivery Preparation Report sees 3 3 Maintenance Inspection
81. ECM does not allow machine to function ECM does not allow machine to function ECM does not allow machine to function ECM does not allow machine to function ECM does not allow machine to function ECM does not allow machine to function ECM does not allow machine to function Fault Code Chart before serial number GS6803 42382 Machine does not operate Engine will not start Machine will not operate Engine will not start Machine will not operate Engine will not start Machine will not operate Engine will not start Machine will not operate from platform Engine will not start Machine will not operate from platform Engine will not start Machine will not operate from platform Genie Defective ECM or platform controls Ground controls engine start toggle switch fault or is activated when the keyswitch is turned on Ground controls engine choke or glow plug toggle switch fault or is activated when the keyswitch is turned on Ground controls platform up down toggle switch fault or is activated when the keyswitch is turned on Platform controls engine choke or glow plug button fault or is activated when the keyswitch is turned on Platform controls engine start button fault or is activated when the keyswitch is turned on Platform controls steer left rocker switch fault or is activated when the keyswitch is turned on Consult Ge
82. GENERATOR RF OUTRIGGER BN18 i Ed PIN29 O gt STARTING AID WH 2 LIFT ENABLE HIGH BN12 JP PIN2 BL ENABLE LOW BN13 PINs o P UP YL PLATFORM amp OUTRIGGER UP DOWN 1621 RD Pouno H1 BK ALARM PIN11 PLATFORM CONTROLS OUTRIGGERS GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 61 July 2007 REV B P1 EMERGENCY STOP PLATFORM KS1 Diesel Models from serial number 40174 to 40939 Electrical Schematic Part 1 of 3 Section 6 Schematics 5 58 2 ow J4 B6 7 i GENERATOR OPTION N m HIGH IDLE a S GENERATOR ON LED i E 2 J2 B8 X S OIL PRESSURE LED p 0 x GLOW PLUG lo E 1287 Ne COOLANT a 5 eR Ji TEMPERATURE LED 26 M ai lt J4 A2 2 J4 B2 OIL PRESSURE SWITCH START A 5 COOLANT E Jas d 7 5 TEMPERATURE SWITCH 22 J4 A5 o 42 E f
83. High Torque Drive Speed ADANGER 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 Note On machines with software revision B1 or lower high torque drive speeds in forward and reverse are simultaneously adjusted resulting in both directions of travel operating at the same speed On machines with software revision CO or higher the high torque forward drive speed and the high torque reverse drive speed may be adjusted independent of one another See 7 2 How to Determine the Revision Level Models with software revision B1 or lower 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 9 REV D a diagnostic display b blue platform up button c lift function enable button d yellow platform down button 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 Press the lift function enable button Use the yellow platform down arrow to scroll to max high tor
84. Lei 7 0 2 S S 9 5 8 9 93 95 z gt 9 9 gt S m z 2 gt lt 3 gt 2 v ou 9 gt gt NE z o gt 2 4 ox 3 4 3 2 z T a 9 m m 5 2 Z 5 m 9 Qu m o 2 0 gt v 2 2 20 212 E z c o m 5 5 2 lt c o o J m 5 e 3 8 c 2 d sz sJ m 3 5 X3 ge d a J g ES 2 lt 2 m Q zi lt 2 m 3 o z m z z zi v o 8 m 5 E 5 m 9 g T 9 2 2 gt z MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7161A n Genie A TEREX COMPANY 6 30 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Electrical Schematic REVA ANSI Models with Gasoline LPG Power from serial number GS6803 42382 to GS6805 43594 Part 2 of 3 f CR8 TERMINAL 30 ABZ BATTERY UM E E T TS e ote HYDRAULIC i f OILCOOLER m M 87 MODELS WITHOUT BATTERY __QUTRIGGERS 623 BK 489919
85. Rev C Inspector company D 1 Scissor arm wear pads Instructions D 2 Hydraulic filter copies of this report to use for D 3 Engine maintenance each inspection Perkins 403C models D 4 Engine maintenance Select the appropriate checklist s for Kubota DF752 models the type of inspection to be performed D 5 Engine maintenance Daily or 8 hours Kubota models Inspection A Perform every 1500 hours Quarterly or 250 hours 2 D 6 Engine maintenance Inspection A B Kubota D905 Semi annually or 500 hours Inspection A B C Comments Annually or 1000 hours Inspection A B C D Two year or 2000 hours Inspection A B C D E Place a check 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 tag and remove the machine from service repair and re inspect it After repair place a check in the box Legend Y yes acceptable no remove from service repaired Genie COMPANY 3 6 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section Scheduled Maintenance Procedures Checklist A Procedures REV C 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 operato
86. WH RD 4 4 4 BK POWER TO PLATFORM STOP RD WH 7 Rb POWER ro GROUND 2 31 BL 1 1 1 1 WH GROUND BK r 2 2 2 2 BL DATALINK HIGH OR 5 5 1 1 5 5 5 1 OR DATA LINK LOW 1 OUTRIGGERS OPTION J5 PIN2 2 D7 PLATFORM CONTROLS VOLTAGE cipio PRINTED CIRCUIT BOARD REGULATOR S8 2 TILT LEVEL J2 PIN1 SENSOR a YL HALL EFFECT 9 7 ERATOE JC1 9 I 9 42 PIN12 JOYSTICK 1812 1813 1814 1815 4 8 e CONTROLLER n0 9 J2PIN13 O LF RF LR RR m O RIG O RIG J2PIN3 UMIT LIMT LIMT o lt o SWITCH SWITCH SWITCH SWITCH 5 E 9 SW5 1 S 5 J5 W6 gt gt NO NOS OR FUNCTION ENABLE 7 2 STEER 1 1 BK i X LEFT RIGHT 1 823 ABBA Qoo 2 a gt J2PIN7 AB27 AB26 16 Tasas fABT L J2PIN8 O 1 J2 PIN14 c c c c c c i oC C 7 9 m g g 8 2 2 8 8 POUTI PIN2 HORN BN5 U5 STARTING AID ELECTRONIC S a CONTROL PIN4 ENGINE START BN2 lt o 50 9 97 qm l i a o d PINs oes
87. be equipped with flashing beacons and the Software set to BEACONS AUTO 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 Of 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 Of OUTRIGGERS ON 15 Use the yellow platform down arrow to scroll to beacons option Result BEACONS 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 Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS 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 f
88. end of the machine Remove the enclosure cover retaining fasteners and the cover A SN gt ue Level sensor after serial number 41199 level sensor b height limit switch CE models c down limit switch d 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 52302 July 2007 Section 4 Repair Procedures REV D 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 ADANGER 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 Connectthe 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 O Result The tilt sensor alarm sh
89. hold the left front outrigger button Pull out the red Emergency Stop button to the on position at the platform controls Continue to hold the auto level button and left front outrigger button for approximately 3 seconds or until a beep is heard Release the buttons 23 Push in the red Emergency Stop button to the off position at the platform controls Section 4 Repair Procedures July 2007 GROUND CONTROLS Confirm the side to side level sensor setting 24 Center a lifting jack under the drive chassis at the ground control side of the machine 25 Raise the machine approximately 6 inches 15 cm 26 Models with RT tires Place a 2 15 x 10 x 10 inch 5 46 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine All other models Place a 2 25 x 10 x 10 inch 5 72 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine 27 Lower the machine onto the blocks 28 Pull out the red Emergency Stop button to the on position at platform controls Start the engine 29 Raise the platform at least 12 feet 3 6 m Result The platform stops raising and the tilt alarm will sound at 180 beeps per minute Result The platform does not stop raising and the tilt alarm does not sound The level sensor must be replaced Repeat this procedure beginning with step 2 Note For reference only the output of the level sensor should be approximately 1 7V
90. max fwd high speed drive Result FWD HIGH SPEED DRIVE is showing in the diagnostic display window 7 Press the lift function enable button 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 Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS a diagnostic display b blue platform up button c liftfunction 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 Section 4 Repair Procedures July 2007 GROUND CONTROLS How to Adjust the
91. output C11 Fuel coil output 12 ECM power input C12 Plug SSS XS XC XC 02 0 BCUXC X XX XeX XXX Electronic Control Module AMOOOOOOOOOO 0 M 36 pin connector Genie TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 5 Section 6 Schematics July 2007 Wiring Diagram Platform Control Box before serial number GS6803 42382 REV P2 2 EMERGENCY STOP EMERGENCY STOP BUTTON BUTTON BK 862 5 RD NA bu RD RD JC4 Q JC4 JOYSTICK JOYSTICK CONTROLLER BN CONTROLLER WH BK 5 WH RD d H 5 U3 U3 ORe PLATFORM WHIBK PLATFORM CONTROLS CONTROLS WH CIRCUIT CIRCUIT WH BL BOARD BOARD PP 2 on m ns SE D7 SW25 D7 5 25 VOLTAGE DIP SWITCH VOLTAGE DIP SWITCH REGULATOR REGULATOR YL PELE Om b nmn m 2 Or 9 BL BK BL WH 16 6 J BK EX v 9 L RD H1 BN12 BN13
92. retaining fastener Use a soft metal drift to remove the pin AWARNING Crushing hazard The lift cylinder will fall if not properly supported 9 Lower the cylinder onto the number 1 center pivot pin 10 Support and secure the entry ladder to an appropriate lifting device Remove the entry ladder mounting fasteners Remove the entry ladder from the machine AWARNING 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 11 Remove the lift cylinder barrel end pivot pin retaining fastener Use a soft metal drift to remove the pin AWARNING 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 AWARNING 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 Part No 52302 Genie GS 2668 RT GS 3268 RT SCISSOR COMPONENTS GS 3268 RT AWARNING 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
93. 1 Check valve proportional circuit Test port 1 Test port 2 Relief valve lift circuit Check valve drive circuit Shuttle valve brake release circuit Check valve drive circuit Relief valve pump 2 Platform up down Priority flow regulator Steer left right Orifice brake release circuit Proportional valve lift drive circuit Brake release Relief valve steer circuit Drive speed select circuit Drive speed select circuit Drive speed select circuit N x xx ici29lo x ov oz er x e i ir Check valve prevents overflowing the drive motors when in high speed AA Check valve prevents engine from running backward when on an incline and reversing direction of travel AB Generator on off AC Flow regulator generator speed AD Relief valve generator circuit AE Platform down AF Shuttle valve brake release circuit AG Pilot operated check valve brake release circuit AH Hand pump brake release circuit Al Needle valve brake release enable AJ Orifice platform down circuit AK Platform overload option BA Relief valve outrigger circuit BB 2 position 2 way solenoid valve outrigger lowering slow BC Orifice outrigger lowering slow BD 3 position 4 way directional valve outrigger cylinder extend retract BE Count
94. 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 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 How to Repair the Kubota DF750 Engine Repair procedures and additonal engine information are available in the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF750 Workshop Manual Kubota part number 97897 00643 Kubota DF750 Operator s Manual REV C 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 5 Coolant Temperature and Oil Pressure Switches See 4 5 Coolant Temperature and Oil Pressure Switches How to Repair the Kubota DF752 Engine Repair procedures and additonal 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 9735
95. 338501 r PLATFORM KS1 AUXILIARY PLATFORM GS 3268RT ONLY JCB1 20A Gasoline LPG Models from serial number 21838 to 38464 Electrical Schematic Part 1 of 3 Section 6 Schematics eb 2 J4 C2 GASOLINE SELECT LPG SELECT i REN x 244 TS3 S 45 FUEL pump o m a HIGH IDLE 5 N 4 LPG SELECT Lc 8 E 4 GENERATOR OPTION DF N GENERATOR ON LED T9856 E 3 5 2 22 88 a gt 4 S OIL PRESSURE LED START o 5 TS52 z 12 COOLANT 5 Ji TEMPERATURE LED 42 45 5 Zug 9 2 J4 A5 in J4 B2 OIL PRESSURE SWITCH J4 B1 e 83 Z COOLANT Pius 9 S TEMPERATURE SWITCH J1 C11 C12 JB X TILT ALARM T Vw i FLASHING BEACON OPTION J4 C3 J4 B4 z le mm 4 lt PLATFORM DOWN 2 g u 95 3268 ONLY or Low 2 Yu Nz og cE Yr 555 cms os lt J1 A9 ree 5 PLATFORM DOWN 8 8 8 8 8 8 8 8 J2
96. 3600 psi 248 2 bar MANIFOLD es 00 57044 HS0027L Genie Part No 52302 GS 2668 RT GS 3268 RT 6 105 Section 6 Schematics July 2007 S Hydraulic Schematic from serial number GS6803 42380 to GS6804 43183 REV B Part 1 of 2 GENERATOR OPTION i ES 69 GENERATOR OUTRIGGERS MANIFOLD OPTION zl DB 4 5 LEFT FRONT RIGHT FRONT i 17 OUTRIGGER OUTRIGGER 12068 4 CB J MEC TREE q OF j 9v pr PM STEER CYLINDER 5 Qurh TEST1 TEST2 Lemn X va Y40 X IIH i Y39 R n 69 vi OUTRIGGER O NE 9 e MANIFOLD 1 x get our 1 I i500 psi EIL 12 1 103 4 bar ex ir RE EET 1 69 FA bz Li pe um
97. 4 Nm 6 35 ft lbs 47 5 Nm 6 27 ft lbs 36 6 Nm 8 60 ft lbs 81 3 Nm 8 40 ft lbs 54 2 Nm 10 105 ft lbs 142 4 Nm 10 63 ft lbs 85 4 Nm 12 140 ft Ibs 190 Nm 12 90 ft lbs 122 Nm 16 210 ft lbs 284 7 Nm 16 120 ft lbs 162 7 Nm 20 260 ft lbs 352 5 Nm 20 140 ft los 190 Nm 24 315 ft lbs 427 1 Nm 24 165 ft lbs 223 7 Nm Genie TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 Section 2 Specifications July 2007 SPECIFICATIONS REV D SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade 8 Black Oxide Bolts LUBED DRY LUBED DRY LUBED Wm mies Nm Nm Nm _ 9 110 140 130 120 760 140 LUBED DRY LUBED DRY LUBED 13 18 74 20 23 33 55 37 14 7 15 8 I 2 m 5 i 0 24 27 1 44 7 50 1 67 8 25 27 44 49 70 33 9 28 4 36 6 32 5 59 6 51 5 66 4 58 3 68 Nm 3 37 5 21 Ca 7 20 64 867 one 12 80 1084 110 1 120 18 90 12 3162 130 m 160 18 130 176 170 230 180 sa 10 20 277 20 366 280 379 220 298 300 306 310 40 19 320 483 430 583 450 60 60 14 30 474 40 637 50 68 60 908 759 480 650 640 867 680 92 90 1233 1044 12 718 710 962 750 1016 950 1342 11
98. 4 QD3 STOP BK ES C BK POWER TO PLATFORM A A A A RD POWER TO GROUND B B B WH GROUND D D 7 D D 4 BL DATA LINK HIGH E E G8 i YL DATA LINK LOW DIAGNOSTIC fee DISPLAY DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR s piles eps eee oe eee Gia oes ek 7 11 MIT a eee ee FUNCTION RD WH JC1 ENABLE fee eG R15 JOYSTICK LS6 LS5 LS1 ene 5K CONTROLLER PLATFORM PLATFORM EXTENSION 2 F i 7 OR POTENTIOMETER DOWN 9 UP DECK 8 WH BK WH YL 71 T E LEVEL 1 o _ SENSOR SW5 SW6 HIGHT 4 4 CIRCUIT WH BL FUNCTION ENABLE T TS66 PIN18 O m 2 4 id O LWH RD 5 E S7 WH gt 5 2 LEVEL L 4 E SENSOR i ME PLATFORM CONTROLS BN MEMBRANE DECAL Pour POWER LED L19 pours M S i 5 PES BOB 5 B B 7 POUT4 O Ly FAULT LED L25 5 QE EE 5 2 91 POUTS o 4 GENERATOR LED 127 U5 2 8 Poure Ed qo HIGH TORQUE LED L21 ELECTRONIC CONTROL MODULE POUT8 4 HIGH IDLE LED L23 4 amp S F 9 1 7 m m 1 1 1 1 gt gt 2 D 8 g g o 3 B8 PS PIN5 4 4 ENGINE STOP BN1 PING e ENGINE START
99. 5 gt lt LEFT REAR E 2 weet 5 OUTRIGGER rof ores T SEA E 699 6 RIGHT FRONT 2 Qete Y Ji B5j N 2 OUTRIGGER 2 o gt lt LEFT FRONT J2 A8 S OUTRIGGER 7 19 9 ZEN 8 Jis PROPORTIONAL n gt FLOW CONTROL a J1 A12 th DRIVE PARALLEL 42 7 lt 2 20 JI ATI DRIVE PARALLEL lt 2d gt E 058 Ac E 0 8 l gt lt i 1 J1 A10 DRIVE PARALLEL Lo enl ntum t tuve J1 A8 1 7 12 DRIVE REVERSE ix sx 0 9 2 Nox 2 ut a7 DRIVE FORWARD 4 gt 1 E S J3 A1 E d J1 A6 2 DRIVE REVERSE 5 9 Zi 0 5 a J1 A5 rt DRIVE FORWARD _______ gt EL J9 2 Q _ BRAKE RELEASE E 28 z 2 e z DOWN t 9 PLATFORM UP Su 5 2 PLATFORM 9 ot P J1 A2 Hr X STEER LEFT o uP K 52 STEER RIGHT 4 6 67 A TEREX COMPANY G 05 2668 RT 05 3268 RT Part No 52302 Section 6 Schematics July 2007 Electrical Schematic Diesel Models from serial number 40940 to 41199 Part 3 of 3 P2 EMERGENCY
100. 559 39 3 5 i o Q gt m 2 2 2 gt 2 2 2 9o m S m gt m m lt E z lt 38 2 3 5 m A T7 8 m gt 5 B 2 gt T T E m a 2 04 gt 2 m n 2 o o 2 gt gt m 2 lt m zd o 2 a gt D 2 B m 2 lt o 2 ES gt gt B m 22 2 m z gt m 2 gt RP 5 5 m m o 2 m 2 8 o zs x E 2 gt m gt o 3 I 2 E g 2 2 9 NOTE ES7162D Part No 52302 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Genie bebe GS 2668 RT GS 3268 RT Section 6 Schematics July 2007 Electrical Schematic ANSI Models with Diesel Power from serial number GS6805 43595 to GS6805 44770 Part 3 of 3 REVA QD4 QD3 P2 Q EMERGENCY WH RD 4 4 4 BK POWER TO PLATFORM STOP RD WH
101. 8 OUTRIGGER m m D UP DOWN m 2 2 0 80 T BK L E J1 PINS o RD H1 MACHINE SHOWN IN THE STOWED ici POSITION WITH THE POWER OFF enie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 33 Section 6 Schematics July 2007 Electrical Schematic ANSI Models with Gasoline LPG Power REV A from serial number GS6805 43595 to GS6805 44770 Part 1 of 3 F9 sa rusE 1 stop ee ME iKS1 ES PLATFORM i CONTROL di 31 GROUND CONTROL 4 4 a AB7 ABS ABS CR41 1 CR23 N C CONTROL CR42 CR5 CR8 ENGINE AUXILIARY 1 HORN IGNI
102. AB7 ABS ABS ABB CR41 1 CR23 N C CONTROL CR42 CR5 CR8 ENGINE AUXILIARY 1 HORN IGNITION START DOWN G6 OF aes HOUR METER 156 PLAT 86 30 O 86 30 2 86 30 5 86 30 4 86 30 8 86 30 6 DOWN EA ERI 85 87 s et 85 a 85 7 85 SWITCH US XZS9899 5 5 A ID d Sera Di Ier BN23 BN91 J2 C4 e AUXILIARYDOWN AUXILIARY DOWN J2 B9 gt gt 5 ee P 130 9 30 CR15 CR4 woRK l MM STARTING HIGH IDLE LIGHTS i AID fq 37 8 86 7 86 ir PENCIL 85 87 85 87 Y7A 10 8 Q8 U32 de gt mes _ FUEL GLOW Q3 21 SHUT PLUG HIGEIDEE 1 OFF OPTION SOLENOID Y8 Y7 Y10 pecs n 4 n i 2 4 2 B RO 8 2 o m 8 k 8 5 55 5392 gt o 9 gt I m po DO c od c t z gt OD lt gt gt Q A gt oS oe n mJ m 9 2 2 oS o z 5 A z v m m z o m o D D gt r 2 3 5 20 22 gt 5 a m 9 5 5 23 L gt z 2 Q Mm 34 m i c g 4 m O mnm 7 6 i S d 2 i 2 m 2 2 zi lt 2 m 3 z o m 2
103. ABS ABS PLATFORM CONTROLS VOLTAGE zy pc PRINTED CIRCUIT BOARD REGULATOR 2 AXIS TILT LEVEL J2 PIN1 SENSOR m A E HALL EFFECT GENERATOR v 3 J2PINi2 o JOYSTICK 1512 1513115141515 3 8 BN CONTROLLER n0 9 42 PIN13 LF RF LR RR O RIG O RIG O RIG J2 PINS LIMT UMT UMT gt o lt o JAPIN SWITCH SWITCH SWITCH SWITCH O ess GY J5PIN3 O j SW5 SW6 NOS 2 datos OR FUNCTION ENABLE 2 E 2 STEER 4 2 x BK i 2 LEFT RIGHT 2 AB23 24 J2 PING gt J2 PIN7 BD AB27 AB26 16 Tasas J2 PIN8 1 J2 PIN14 c c c c c c c c C T T T 7 Pp P N ms DNI 9 2 9 92 2 8 8 i z l POUTI PIN2 HORN BN5 U5 PIN3 STARTING AID BN3 ELECTRONIC CONTROL PIN4 ENGINE START BN2 c E e 65 MODULE T wo T T ti a 5 PINS HIGH TORQUE BN6 dc ME MM lasi 6 GENERATOR BN7 qase 7 ABS PIN7 s LPG SELECT BN14 NE a Ape PINS Y36 Y34 Y40 44 1 4 4 n NM C Al X A AC 1 1 I PINS LF OUTRIGGER ENABLE BN85 000 i i 120000000000 Nt 0 RF OUTRIGGER ENABLE BN86 ACOX EE E o LR OUTRIGGER ENABLE BN87 Y35 PIN12 O RR OUTRIGGER ENABLE BN24 i i
104. B PROCEDURES 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 1 3 Controller Adjustments GS 2668 RT before serial number 26563 and GS 3268 RT before serial number 42000 7 Raise the platform to full height 8 Fully extend the platform extension 9 Slowly move the joystick to the full drive position O Result The drive function should not operate 10 Lower the platform or retract the platform extension to drive Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST B PROCEDURES 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 T3 Explosion and fire hazard Engine A DANGER fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extingu
105. B11 T 4 ic i ic po EA ir e C 5 e wel x e x asl ot oom wl uem ux r AUTOMOTIVE STYLE HORN at 5 OPTION o o 7 WORK LIGHTS OPTION al 3 HIGH IDLE SOLENOID Im af N Cj CHOKE 4 4 g 5 HOURMETER cog 9 s o Lu EHE ueee m Oft 4 SPARK PLUG S z 5 O 8158 25 4 1 4 4 DISTRIBUTOR 5 2 0 119 lt 2 IGNITION COIL 0000 1 5 E 4 fft Eus 8 ALTERNATOR gt 9 pa 4 I gt NN LE 95 e 2 4 ENGINE STARTER o al gt z 2 Lu e z 5 Qo gt PU um 4 SD 52302 enie GS 2668 RT GS 3268 RT ATE 6 14 Part 2 of 3 Section 6 Schematics Electrical Schematic Gasoline LPG Models from serial number 21838 to 38464 July 2007 REV C pom s O2 a O pomme Gl TINN 1 J1 C7 C8 07 8 2
106. CR4 woRK STARTING HIGH IDLE LIGHTS AID gig x 9 x is a id 118 d DA zs FIR Lol 857 D 126 Y7A 10 5 lt gt 2 08 U32 cx 4700uF 1 FUEL GLOW Q3 21 SHUT PLUG HIGHIDLE B OFF OPTION SOLENOID Y7 Y10 2 1 pecs n 4 n i 2 4 5 8 5 8 B 8 i i 9394 gt o 9 gt I m po DO ox c 5 5 z 2 row lt gt gt m m 2 o A A oS se g 9 3 4j 2 9 2 z 222 95 5 m m 2 5 2 o D D gt r 2 3 5 20 22 gt 3 9 a m 9 5 5 23 L zi m 5 m 9 5 o T Q c o 2 52 5 a E o 9 d 2 i lt m Q zi lt 2 m 3 z o m 2 5 z d 6 z o m o 5 D o z z E 5 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF canis Genie A TEREX COMPANY GS 2668 GS 3268 RT Part No 52302 July 2007 Section 6 Schematics REVA Electrical Schematic ANSI Models with Diesel Power from serial number GS6803 42382 to GS6805 43594 Part 2 of 3
107. 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 30 Raise the machine slightly 31 Remove the blocks from under both wheels Genie 4 68 GS 2668 RT GS 3268 RT REV D 32 Lower the machine and remove the jack 33 Center lifting jack under the drive chassis at the tank side of the machine 34 Raise the machine approximately 6 inches 15 cm 35 Models with RT tires Place a 2 15 x 10 x 10 inch 5 46 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine All other models Place a 2 25 x 10 x 10 inch 5 72 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine 36 Lower the machine onto the blocks 37 Raise the platform at least 12 feet 3 6 m O 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 38 Lower the platform to the stowed position 39 Raise the machine slightly 40 Remove the blocks from under both wheels 41 Lowe
108. HIGH IDLE BN4 PIN24 O RROUTRIGGER BN24 E OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 e PIN25 e GENERATOR RF OUTRIGGER BN18 i Ed PIN29 O gt STARTING AID WH 2 LIFT ENABLE HIGH BN12 JP PIN2 BL ENABLE LOW BN13 PINs o P UP YL PLATFORM amp OUTRIGGER UP DOWN 1621 RD Pouno H1 BK ALARM PIN11 PLATFORM CONTROLS OUTRIGGERS GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 73 July 2007 Section 6 Schematics Electrical Schematic REVA Diesel Models from serial number 41824 to GS6803 42381 Part 1 of 3 1J4 A2 2 eese etes BN68 START ELECTRONIC CONTROL MODULE J2 A5 CR43 86 J4 A5 J4 B5 C2 33000 uf J1 C11 C12 94 4 POWER CR25 R7 20000 ENGINE RUN CR15 GLOW J4 C3 J4 B4 J4 C1 C4 85 ENGINE START CR1 85 86 87 30 PLUG CR4 30 HIGH IDLE J4 B6 J2 B8 L27 o 25 GENERATOR OPTION M 18 GENERATOR O
109. LPG Power REV B from serial number GS6803 42382 to GS6805 43594 Part 1 of 3 KS1 P1 B 21 Q EMERGENCY STOP 04 gt x PLATFORM CONTROL 4 d 1 Hi oe i GROUND VIGOMIROE l ABl C CB2 20a nea T PS2 Y PLATFORM OVERLOAD t PRESSURE SWITCH AB20 CR41 CR1 CR23 6 CONTROL CR42 CR5 CR8 ENGINE AUXILIARY SYSTEM POWER HORN IGNITION START DOWN OF LS6 PLAT 86 86 2 86 86 3o 86 A 86 DOWN E 0 LIMIT 85 s 85 850 et 8 85 SWITCH AB21 5 em ZE8289 BLS 5 S 5 I E nee a SE 8 8 EXCT 9 01 idi BN23 91 4264 0 lt AUXILIARY DOWN AUXILIARY DOWN U19 p J2B9 5 CR15 130 eT STARTING e AID CR4
110. O ul no oo oo DOJN 0 2 o co OLR oy PON Ao ala rojo io N N EN E e ER e zi E Em e m ol oo fN NI ofo o Co fro N D OO NI NJ 09 AY Co Oy Copco o Pol A A O NI ES ES Es hyo Co beard A e A K 85 0 570 562 TEREX COMPANY 2 10 GS 2668 GS 3268 RT Part No 52302 July 2007 Section 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 AWARNING 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
111. OR wiring FAULT 60 Drives slow or not at all when FORWARD 1 Red Forward 1 coil Y6 fault elevated Troubleshoot coil OR wiring FAULT 61 Drives slow or not at all when REVERSE 1 COIL Red Reverse 1 coil Y5 fault elevated Troubleshoot coil OR wiring FAULT 62 Drives slow not at all when FORWARD 2 COIL Red Forward 2 coil Y6A fault elevated Troubleshoot coil OR wiring FAULT 63 Drives slow or not at all when REVERSE 2 COIL Red Reverse 2 coil Y5A fault elevated Troubleshoot coil OR wiring FAULT enie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 5 Fault Codes REV FAULT CODE CHART FROM SERIAL NUMBER GS6803 42382 TO GS6805 44770 Fault Code LED Condition Result Solution 66 Check the engine oil level OR check wiring from the oil pressure switch to LOW OIL Red Low oil pressure Engine stops ECM PRESSURE OR replace the oil pressure switch Gasoline LPG models Check the engine radiator coolant level OR check the wiring from the water temperature 67 High engine temperature OR switch to ECM OR replace the water HIGH COOLANT Red High coolant temperature defective engine coolant or oil temperature switch TEMPERATURE temperature switch Diesel models Check the engine oil level OR check the wiring from the oil temperature switch to ECM OR replace the oil
112. PLATFORM LIFT platform controls Lint functioi disabled circuit board at platform controls SW FAULT 30 Replace up down switch at platform OFF NEUTRAL Red Up down switch off neutral Up down function disabled controls LIFT JOYSTICK 3 Starting aid fault at the m Troubleshoot button OR replace printed PLATFORM HORE EN Red platform controls Starting aid disabled circuit board at platform controls FAULT 32 Engine start button fault at Troubleshoot button OR replace printed PLATFORM Red platform controls Engine will not start circuit board at platform controls START SW FAULT 33 Red s 1 1 enable Outriggers disabled Troubleshoot button OR replace printed LEFT FRONT M at praorm 99 circuit board at platform controls OUTRIG SW FLT controls enie Part No 52302 A TEREX COMPANY GS 2668 RT GS 3268 RT Section 5 Fault Codes July 2007 FAULT CODE CHART FROM SERIAL NUMBER GS6803 42382 TO GS6805 44770 REVA Fault Code LED Condition Result Solution 34 Right front outrigger enable Troubleshoot button OR replace printed RIGHT FRONT Red button fault at platform Outriggers disabled circuit board at platform controls OUTRIG SW FLT controls 35 Left rear outrigger enable Troubleshoot button OR replace printed LEFT REAR Red button fault at platform Outriggers disabled circuit board at platfor
113. Repair Procedures REV D 7 6 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 TITI Tip over hazard Failure to install ADANGER 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 11 2 Before serial number 41200 Remove the ground control panel retaining fasteners and open the panel Locate the level sensor behind the ground control panel Proceed to step 7 Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS After serial number 41199 3 Raise the platform approximately 10 feet 3
114. SE 1 CR17 s qe o HYDRAULIC OILCOOLER ipd 57 on d MODELS WITHOUT BATTERY QUTRIGGERS 8294 05 5 ELECTRONIC CONTROL MODULE Y4 y1 Y1B Y6 Y6A Y9 4 X EX DZ O X EFX X NE SW ped Y3 Y1A Y2 Y5 Y5A Y29 7 Z WAT ue m T 85 id B8 9 9 23 9 o 2 2 2 5 m gt E m 2 E y T D 9 m T 2 85 2 5 3 9 2 3 2 9 D 42 d 5 S d 3 Eg E 2 BZ 7 205 5 eea eer 5 50 9 S 7 8 5 9 S 2 9 E g NOTE MACHINE SHOWN IN THE STOWED ES7162A POSITION WITH THE POWER OFF Genio Part No 52302 A TEREX COMPANY GS 2668 RT GS 3268 RT Section 6 Schematics July 2007 Electrical Schematic CE Models with Diesel Power from serial number GS6803 42382 to GS6805 43594 Part 3 of 3 REV B
115. Specifications 1 Raise the platform approximately 10 feet 3 m 2 Liftthe 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 AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform Genie GS 2668 RT GS 3268 RT REV Note alpha callouts refer to corresponding notes on the hydraulic schematic GS 2668 RT a platform down solenoid valve b lift cylinder C pressure switch CE models 4 Tag and disconnect the wiring from the solenoid valve at the barrel end of the lift cylinder 5 Before serial number 40207 Tag and disconnect the manual lowering cable from the solenoid Note During assembly the manual platform lowering cable needs to be properly adjusted See 6 1 How to Adjust the Manual Platform Lowering Cable 6 Tag disconnect and plug the hydraulic hose from the lift cylinder Cap the fitting on the cylinder AWARNING 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 52302 July 2007 Section 4 Repair Procedures REV 7 Attach a strap from an overhead crane or similar lifting device to the rod end of the lift cylinder for support 8 Remove the lift cylinder rod end pivot pin
116. TOO MUCH WEIGHT IN PLATFORM PUT CORRECT RATED LOAD IN PLATFORM PRESSURE SWITCH OUT OF ADJUSTMENT REV B 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 TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS AND TURN BACK ON TURN THE PRESSURE SWITCH NUT 1 4 TURN INTO THE HYDRAULIC LINE PROPERLY AT DOWN LIMIT WITH RATED LOAD IN PLATFORM THE PRESSURE SWITCH ALARM CONTINUES TO SOUND DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCH TOO MUCH WEIGHT IN PLATFORM OVERLOAD SYSTEM NOT ADJUSTED PROPERLY BATTERIES ARE NOT FULLY CHARGED OVERLOAD SYSTEM NOT ADJUSTED SLIDER CHANNEL NOT LUBRICATED LUBRICATE SLIDER CHANNELS SYSTEM NEEDS TO BE RESET CHARGE BATTERIES REPEAT CALIBRATION PROCEDURE TURN OFF RED EMERGENCY STOP BUTTON WAIT THREE SECONDS AND TURN BACK ON PUT CORRECT RATED LOAD IN PLATFORM TURN THE PRESSURE SWITCH NUT 1 4 TURN INTO THE HYDRAULIC LINE OR REPEAT CALIBRATION
117. Test the Drive Speed Raised Position Genie Part No 52302 GS 2668 RT GS 3268 RT 4 7 Section 4 Repair Procedures PLATFORM CONTROLS How to Adjust the Fast Lift Speed 1 Remove the platform controls from the platform and place the controls near the diagnostic display at the ground control panel 2 Turn key switch to the off position 3 Models without outriggers Press and hold the horn button and platform extend retract enable button then turn the key switch to platform controls Models with outriggers Press and hold the horn button and the outrigger enable button then turn the key switch to platform controls Result The diagnostic display window at the ground controls will show PS Note The PS showing in the diagnostic display window indicates that the ECM is in the programming mode 4 Release the horn button and the platform extend retract enable button or outrigger enable button 5 Press and hold the function enable high speed select button to show the fast platform lift speed percentage in the diagnostic display window 6 Toincrease or decrease the fast platform lift speed press and hold the function enable high speed select button while using the steering rocker switch to adjust the percentage 7 Release the function enable high speed select button Genie 4 8 GS 2668 RT GS 3268 RT July 2007 REV C 6 U e Po
118. above the fuel filter to the open position Genie GS 2668 RT GS 3268 RT REV C C 3 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil 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 Part No 52302 July 2007 Section Scheduled Maintenance Procedures REV C CHECKLIST C PROCEDURES C 4 C 5 Perform Engine Maintenance Diesel Models Engine specifications require that this procedure be performed every 500 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Kubota D905 Operator s Manual Perform Engine Maintenance Kubota D905 and DF750 Models Engine specifications require that this procedure be performed every 800 hours Required maintenance procedures and additional engine information is available in
119. at the non steer end of the machine 54 Lower the machine onto the blocks 55 Raise the platform at least 12 feet 3 6 m Result The platform stops raising and the tilt alarm will sound at 180 beeps per minute Result The platform does not stop raising and the tilt alarm does not sound The level sensor must be replaced Repeat this procedure beginning with step 2 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 56 Lower the platform to the stowed position 57 Raise the machine slightly 58 Remove the blocks from under both wheels 59 Lower the machine and remove the jack 60 Turn the key switch to the off position Section 4 Repair Procedures July 2007 Hydraulic Pump 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 Two Hydraulic Hose and Fitting Torque Specifications How to Test the Hydraulic Pump 1 Tag disconnect an
120. battery and connect the wires 6 Close the ground control panel and install the fasteners 7 Close the ground controls cover Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS 7 2 Function Speed Tuning from serial number GS6803 42382 to GS6805 44770 All machine function speeds are determined by the percentage of total ECM voltage output The speeds of the following machine functions may be adjusted to compensate for wear in the hydraulic pump and drive motors Stowed drive speed High torque drive speed Raised drive speed Platform lift speed To adjust the function speeds on machines before serial number GS6803 42382 see 1 3 Function Speed Tuning before serial number GS6803 42382 For further information or assistance consult the Genie Industries Service Department ry Tip over hazard Do not adjust the ADANGER 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 LU T3173 lip over hazard This procedure ADANGER 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 cont
121. 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 Section 4 Repair Procedures July 2007 Fuel and Hydraulic Tanks 10 1 Fuel Tank How to Remove the Fuel Tank ADANGER ADANGER ADANGER po Explosion and fire hazard Engine fuels are combustible Remove the fuel tank in an open well ventilated 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 Remove the fuel filler cap from the tank 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 GS 2668 RT
122. down to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Remove the hose cover plate mounting fasteners Remove the cover Part No 52302 Genie GS 2668 RT GS 3268 RT FUEL AND HYDRAULIC TANKS 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 AWARNING 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 Section 4 Repair Procedures July 2007 Steer Axle Components 1
123. e 06 1 POUT7 O D 4 E 4 LPG LED L22 POUT8 O HIGH IDLE LED 123 PINS a ENGINE STOP BN1 E PING ENGINE START BN2 Ed PIN10 O HIGH IDLE E PIN19 4 HORN BN5 T PIN23 O HIGH TORQUE BN6 PIN24 E GENERATOR BN7 JE PIN13 O LPG SELECT BN14 E PIN25 O PLATFORM EXT RET ENABLE BN16 T PIN29 4 STARTING AID RD BL PINs 9 DOWN POUT1 PIN11 O H1 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 WH GROUND BK POWER TO PLATFORM RD POWER TO GROUND REV P2 EMERGENCY a STOP BL DATA LINK HIGH YL LOW enie A TEREX COMPANY PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR 15 JOYSTICK 246 9 5K CONTROLLER MS POTENTIOMETER PP 8 WH BK WH YL 50 5 FUNCTION ENABLE T VBL 5 2 0 bd PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 LIFT ERROR INDICATOR LED L57 FAULT LED L25 GENERATOR LED L27 HIGH TORQUE LED 121
124. 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 32 Lower the platform to the stowed position 33 Raise the machine slightly 34 Remove the blocks from under both wheels 35 Lower the machine and remove the jack 36 Remove the blocks from the wheels at the steer end of the machine 37 Center a lifting jack under the drive chassis at the ground controls side of the machine 38 Raise the machine approximately 4 inches 10 cm Section 4 Repair Procedures July 2007 GROUND CONTROLS 39 Models with RT tires Place a 1 85 x 10 x 10 inch 4 7 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine Models with non marking tires Place a 1 94 x 10 x 10 inch 4 93 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine Models with industrial tires Place a 1 95 x 10 x 10 inch 4 95 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine 40 Lower the machine onto the blocks 41 Before serial number 41137 Raise the platform at least 12 feet 3 6 m O Result The tilt alarm does not sound and all functions will operate Proceed to step 43 Result
125. grease to the DIP switch after setting the configuration 6 Close the lid and install the platform control box lid fasteners Part No 52302 Genie bebe Release the toggle switches push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position GS 2668 RT GS 3268 RT 4 11 Section 4 Repair Procedures July 2007 PLATFORM CONTROLS REV DIP Switch Codes Chart sl le A inthe column indicate that the machine Diagnostic amp EG 8 2 configuration includes this option Display lt a 56 259 355 8 38 58 218 8 5 9 gt 4290 20 Diagnostic 0 5 8 5 49 01110000 i 399812 818 omo nie s 8335883178 e _ eas 5 2 6 6 26 s os 55 01110010 fe e v fomo fromm __ s omm o w oe 62 01111000 Eun Som pee amp oono e sw 8 fete tet fe amp foomo e CR ER UR E amp ae sora ee e _ 71 01111100 7
126. 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 Part No 52302 July 2007 Section 4 Repair Procedures ____ REV D MANIFOLDS 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
127. 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 Liftthe 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 AWARNING 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 Genie GS 2668 RT GS 3268 RT REV B 5 Locate the hose cover plate in the center of the drive chassis Remove the hose cover plate mounting fasteners and remove the cover 6 If equipped close the two hydraulic shutoff valves located at the hydraulic tank 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 Pl
128. is 5 16 inch 8 mm or more Proceed to step 4 Result The measurement is less than 5 6 inch 8 mm Replace both wear pads 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 Genie 3 30 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section Scheduled Maintenance Procedures REV 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 ACAUTION 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 AWARNING SA injury hazard Spraying ydraulic 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 Part No 52302
129. l HeNi a z J2 B10 J2 A6 J2 C1 C10 3 DATA LINK YL J2 B3 LY O E uaas 1 9283 225 AUTO LEVELING Iz DATAUNK BK a4 J2 B1 35 SENSOR TA 7 adu 2 GROUND FROM PLATFORM j3 g 2 810 m OUTRIGGER EXTEND z d gt SLOW J3 B5 J1 B7 OUTRIGGER RETRACT lt Q gt E 9 0 2 Q E J1 B6 OUTRIGGER EXTEND E 1 B e ANT d xs RIGHT REAR 188 5 B OUTRIGGER d 5 gt lt LEFT REAR 2 18 OUTRIGGER ro EER T 5 8 nomino D gt s 2 o gt lt 19 LEFT FRONT J2 A8 9 T5 A Pal D TS OUTRIGGER gt M E z p 8 l gt lt 4 9 PROPORTIONAL gt FLOW CONTROL l gt K m 2 4 J2 A7 J1 A12 thi DRIVE PARALLEL 8 gt i 0658 6 Dd amp ig 2 lt 1 6 su JI AT t Rar DRIVE PARALLEL 28 a JI A10 to 422 DRIVE PARALLEL lt fa fences due J1 A8 tH 12 DRIVE REVERSE 5 ki J9 A3 7 55 di lt 328 Noe 2 J1 A7 tor DRIVE FORWARD 2278 2 gt E 1408 u ui mu J3 A1 _ ite ERE mas g TUI DRIVE REVERSE 8 G42 He 3
130. 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 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 Lowerthe 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 REV D Models before serial number GS6803 42382 and after serial number GS6803 42381 with software revision B1 or lower 6 Bring the machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Continue at full speed and note the time when the machine reference point passes over the finish line Refer to Section 2 Specifications Models after serial number GS6803 42381 with software revision CO or higher 6 Genie GS 2668 RT GS 3268 RT 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 Continue at full speed and note the time when the m
131. mg m m m m m ES c m m m g 49 24 22 1 22 D 2 2 5 gt gt gt E 25 m 2 m z KR 8 8 m B RB RF 28 D 5 9 MACHINE SHOWN IN THE STOWED ES7140P POSITION WITH THE POWER OFF enie A TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 71 Section 6 Schematics July 2007 Electrical Schematic Diesel Models from serial number 41200 to 41823 Part 3 of 3 P2 EMERGENCY STOP C c L BK POWER TO PLATFORM A A RD POWER TO GROUND B B Lwa eroun opos opoz i D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE B B WH GROUND C j C BK POWER TO PLATFORM yr A A RD POWER TO GROUND L REV B P2 EMERGENCY a STOP D D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS VOLTAGE REGULATOR PRINTED CIRCUIT BOARD REGULATOR BN R15 JOYSTICK gt 5K CONTROLLER POTENTIOMETER LPP 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE LERIZRIGHIT PIN18 WHEE 4 PLATFORM CONTROLS MEMBRANE DECAL POUT4 POWER LED L19 POUTS POUT6 29
132. of motion Machines after serial number GS6803 42381 are equipped with Hall effect joysticks which do not require calibration How to Calibrate the Joystick before serial number GS6803 42382 Note If the joystick is out of calibration fault code 30 will be present on the diagnostic display and the error indicator light will be illuminated at the platform controls 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Remove the platform control box lid retaining fasteners Open the control box lid AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Section 4 Repair Procedures July 2007 PLATFORM CONTROLS 3 Locate the potentiometer on the base of the joystick CONTROLLER O PLATFORM CONTROLS CIRCUIT 00000000 joystick controller JC1 potentiometer shaft slot potentiometer shaft set screw platform controls circuit board U3 potentiometer brown wire purple wire 4 Using volt meter to read DC voltage place the voltmeter negative lead on the purple wire Place the volt meter positive lead on the brown wire AWAR
133. on position at both the ground and platform controls 12 Set a multimeter to read DC voltage Adjust the side to side axis 13 Without disconnecting the wire harness from the level sensor connect the negative lead of the multimeter to the black wire at the level sensor 14 Without disconnecting the wire harness from the level sensor connect the positive lead of the multimeter to the yellow wire at the level sensor Genie GS 2668 RT GS 3268 RT MODELS WITH OUTRIGGERS MS 2 X e 5 BEFORE el 7 SERIAL NUMBER gt 41200 REV Level sensor models without outriggers chassis level sensor Y indicator X indicator x er ET M 9 MODELS WITH OUTRIGGERS ANN AFTER SERIAL NUMBER 41199 Part No 52302 July 2007 Section 4 Repair Procedures REV D 15 Adjust the Y axis side to side to 2 5V DC Tap the top of the level sensor lightly with fingers after each turn of an adjusting nut ADANGER 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
134. outer arm index 27 from the engine side of the machine Crushing hazard The number 2 AWARNING outer arm index 27 at the engine side could become unbalanced and fall if not properly supported when removed from the machine 71 Support the number 1 outer arm index 30 with a second overhead crane at the steer end 72 Remove the external snap rings from the number 2 pivot pin index 12 at the steer end Part No 52302 Genie GS 2668 RT GS 3268 RT SCISSOR COMPONENTS 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 AWARNING 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 AWARNING 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 AWARNING 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 wir
135. outlet AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 12 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 July 2007 Section 4 Repair Procedures REVA 13 Support the platform with a forklift at the steer end of the machine Do not apply any lifting pressure 14 Attach a strap from the platform railings to the carriage on the forklift to support the platform 15 Remove the retaining fasteners from the platform pivot pins at the steer end of the machine 16 Use a slide hammer to remove the pins AWARNING Crushing hazard The platform will fall when the pivot pins are removed if not properly supported by the forklift 17 Remove the retaining fasteners from the platform pivot pins at the non steer end of the machine 18 Use a slide hammer to remove the pins AWARNING Crushing hazard The platform will fall when the pivot pins are removed if not properly supported by the forklift 19 Carefully lift the platform off of the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The platform will become unbalanced and fall
136. outriggers Level sensor after serial number 41199 a chassis b level sensor a level sensor X indicator b height limit switch CE models d Y indicator c down limit switch d load sense delay limit switch CE models models Y moet 14 Tag and disconnect the wire harness from the e X lt level sensor 15 Remove the fasteners securing the level sensor E to the chassis Remove the level sensor from the machine MODELS 16 Install the new level sensor onto the machine WITHOUT with the Y on the level sensor base closest to OUTRIGGERS the steer end of the machine Install and tighten the level sensor retaining fasteners ADANGER 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 AFTER machine Failure to install the tilt LA w SERIAL NUMBER level sensor as instructed will N 41199 x cause the machine to tip over resulting in death or serious injury Genie 4 58 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV D 17 Connect the wire harness to the level sensor 18 Pull out the red Emergency Stop button to the on position at the platform controls 19 Tighten the level sensor adjusting fasteners until the bubble in the top of the level sensor is centered in the circles N
137. 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 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 Part No 52302 Genie bebe 5 Tag disconnect and plug the hydraulic hoses from the drive motor and brake Cap the fittings on the drive motor and brake AWARNING 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 ACAUTION Crushing hazard The driv
138. ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron Ill 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 Petro Canada Environ MV 46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable UCON Hydrolube HP 5046 Quintolubric 822 Fire resistant Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 may result in component damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below O 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 Genie TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 2 Specifications REV D Function pump Type 2 section pressure balanced gear pump D
139. pressure dissipate gradually Do not allow oil to squirt Read understand and obey the safety rules or spray and operating instructions in the appropriate operator s manual on your machine General Repair Process Be sure that all necessary tools and test equipment are available and ready for use Malfunction Identify Troubleshoot discovered symptoms Perform repair problem still exists Retum to Service solved Genie Part No 52302 GS 2668 RT GS 3268 RT 6 1 Section 6 Schematics July 2007 Electronic Control Module Layout before serial number GS6803 42382 REV A 4 gt wan e AON Function manifold Engine J4 Electronic Control Module J1 J2 Flashing beacon Genie cha Platform controls GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics E Electronic Control Module Pin Out Legend REV A before serial number GS6803 42382 J1 Connector J2 Connector J3 Connector 36 pin 36 pin 18 pin A1 Steer right A1 Platform up input switch input platform up 2 Steer left Y4 A2 Platform down input A2 Limit switch input platform down AS Platform up Y8 A3 Not used switch input extension deck A4 Brake release Y2 A4 N
140. red Emergency Stop button to the off position at the ground controls 11 Check the raised drive speed of the machine Refer to the Maintenance procedure B 11 Test the Drive Speed Raised Position Part No 52302 July 2007 Section 4 Repair Procedures REV D Models with software revision or higher 1 Pull out the red Emergency Stop button to the on position at the platform controls 2 Pushin 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 Pressthe lift function enable button 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 Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS a diagnostic display b blue platform up button c liftfunction enable button d yellow platform down button 9 Press the lift f
141. return pipe at the injectors Clean up any fuel that may have spilled Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST C PROCEDURES 3 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Section 2 Specifications for tank capacity ADANGER 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 Tagand remove the hoses and fittings from the top of the tank 6 Rinse out the inside of the tank using a mild solvent 7 Install the hoses and fittings removed in step 5 into the top of the tank 8 Install the tank into the machine as you route the hoses through the bulkhead Install and tighten the tank retaining fasteners to specification Torque specifications Fuel tank retaining fasteners dry 175 in lbs 19 8 Nm Fuel tank retaining fasteners lubricated 131 in lbs 14 8 Nm 9 Install the fuel supply and return hoses onto the filter head and the fuel return pipe at the injectors Tighten the clamps 10 Models with fuel shutoff valve Turn the manual fuel shutoff valve located
142. sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 that your air temperature increases or decreases from 68 F 20 Valve Coil Resistance Specifications Description Specification valve 3 position 4 way 40 12V DC with diode schematic items A and B Solenoid valve 2 position 4 way 7 5Q 12V DC with diode schematic item P Solenoid valve 3 position 4 way 7 5Q 12V DC with diode schematic item R Proportional valve 12V DC schematic item Solenoid valve 2 position 2 way 9 50 12V DC with diode schematic items U W X and Y Solenoid valve 2 position 2 way 90 12V DC with diode schematic item AI Solenoid valve 2 position 2 way 7 5Q 12V DC schematic item BB Solenoid valve 3 position 4 way 7 5Q 12V DC schematic item BD Solenoid valve 2 position 2 way 8 20 10V DC schematic items CA CB CC and CD Solenoid valve 2 position 3 way 60 12V DC schematic item DA Part No 52302 Spikes Voltage spikes naturally occur within a July 2007 Section 4 Repair Procedures REV D MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in COIL many valve coils Properly functioning coil diodes Om A MULTI protect the electrical circuit by suppressing voltage METER function circuit following the interruption of electrical current
143. 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 over temperature 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 52302 Genie GS 2668 RT GS 3268 RT KUBOTA D905 ENGINE Clark a coolant temperature switch b oil pressure switch 2 Tag and disconnect the wiring from the switch Remove the switch from the engine Bodily injury hazard Contact with ACAUTION 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 Section 4 Repair Procedures July 2007 Kubota DF750 DF752 Engine 5
144. 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 AWARNING outer arm index 7 at the ground controls side could become unbalanced and fall if not properly supported when removed from the machine Section 4 Repair Procedures July 2007 SCISSOR COMPONENTS 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 AWARNING outer arm index 7 at the engine side could become unbalanced and fall if not properly supported when removed from the ma
145. the oil pressure switch A TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT Section 5 Fault Codes July 2007 FAULT CODE CHART REV B BEFORE SERIAL NUMBER GS6803 42382 Check the engine radiator coolant level OR check wiring and High engine terminal at the water temperature OR temperature switch defective water OR check the wiring temperature switch and terminal at the ECM OR replace the water temperature switch Check battery or ECM does not allow All functions do not Low supply voltage to alternator condition E machine to function operate ECM Stop relay 1 amp 2 terminals ECM does not allow Engine statis and Engine idle RPM too Consult Genle runs then shuts Industries Service machine to function low down Department ECM does not allow Engine starts and Consult Genie 70 runs then shuts Engine RPM too high Industries Service machine to function down Department Engine will not start or run OR engine runs then shuts off ECM does not allow machine to function Genie A TEREX COMPANY 5 8 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 5 Fault Codes REVA from serial number GS6803 42382 to GS6805 44770 Fault Code LED Condition Result Solution SYSTEM READY Green Normal operation INTERNAL ECU Red Internal ECM error System shutdown Replace ECM FAULT 02 P
146. the platform Refer to the chart below GS 2668 975 kg GS 3268 919 kg 8 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine 9 Raise the platform to approximately 4 m 10 Rotate the safety arm away from the machine and let it hang down 11 Before serial number GS6805 44169 Remove the cover from the pressure switch After serial number GS6805 44168 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 Part No 52302 July 2007 Section 4 Repair Procedures REV B 12 Before serial number GS6805 44169 Using a wrench slowly turn the nut of the platform overload pressure switch one quarter turn into the hydraulic line After serial number GS6805 44168 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 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
147. this procedure is available in the Kubota D905 Workshop Manual Kubota part number 97897 02432 Kubota D905 Workshop Manual Genie part number 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 10 2 Ifthe ohm reading is different than 19 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 80 for each individual glow plug 3 Install the connector plate and wires to all three glow plugs 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position 5 Connect the red positive lead from a volt meter to the number three glow plug Connect the black negative lead to ground 6 Hold the glow plug switch in the on position Result The volt meter should read 12V DC or more Part No 52302 Genie GS 2668 RT GS 3268 RT Kubota D905 Engine 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 th
148. travel operating at the same speed On machines with software revision CO or higher the raised forward drive speed and the raised reverse drive speed may be adjusted independent of one another See 7 2 How to Determine the Revision Level Models with software revision B1 or lower 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 is showing in the diagnostic display window The ECM is now in programming mode Genie GS 2668 RT GS 3268 RT REV D O a diagnostic display b platform up button c lift function enable button d yellow platform down button 5 Pressthe lift function enable button 6 Use the yellow platform down arrow to scroll to raised drive speed Result RAISED DRIVE SPEED is showing in the diagnostic display window 7 Pressthe lift function enable button 8 Press the yellow platform down button to decrease the raised drive speed or press the blue platform up button to increase the raised drive speed Refer to Section 2 Specifications 9 Press the lift function enable button 10 Push in the
149. 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 Part No 52302 Genie GS 2668 RT GS 3268 RT PLATFORM COMPONENTS 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 Liftthe platform extension lock handle 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 GS 2668 RT before serial number 26563 and GS 3268 RT before serial number 41200 Remove the platform extension limit switch mounting fasteners and remove the limit switch Do not disconnect the wiring 10 Remove the platform controls from the platform and lay them off to the side Section 4 Repair Procedures July 2007 PLAT
150. woo gt CERCON ESL EPROR m woon 29 oomoo T T 74 1000191 e e omno _ s 3 f Po fet fet m omom _ s ooon fe foomo s f n s foomo e T ER s omon s eon e s pomot Tele 88 1000101 fefefe er aT ee s foomo _ 5 oomo T a s foomo 3 fomo a omon 1 4 e omo onn 4 Genie PN A GS 2668 GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV C PLATFORM CONTROLS 8151 18 E Diagnostic s E 8 5 5 Diagnostic T E 8 5 5 Display 9 55 9 55 pede 5 5 5 538 57 E e 5895 ER 3 5 8 9 8128 gt 1290 6535206839 ar m 1 o moo 1 m 000170 LEES p ESL I
151. 02 July 2007 Section 4 Repair Procedures REV C 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 AWARNING 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 AWARNING Crushing hazard The number 3 inner arm index 16 could become unbalanced and fall if not properly supported when removed from the machine Part No 52302 Genie GS 2668 RT GS 3268 RT SCISSOR COMPONENTS 43 Attach a lifting strap from
152. 02 7 5 o m o m p TUE 3 E m 2 5 amp 6 8 MACHINE SHOWN IN THE STOWED ES0116V POSITION WITH THE POWER OFF Genie COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 27 Section 6 Schematics July 2007 Electrical Schematic Gasoline LPG Models from serial number 41824 to GS6803 42381 Part 3 of 3 QD3 BK POWER TO PLATFORM A J A y RD POWER TO GROUND B l WH GROUND 0 D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS PRINTED CIRCUIT BOARD P2 EMERGENCY a STOP VOLTAGE REGULATOR BN R15 JOYSTICK gt 5K CONTROLLER 17 POTENTIOMETER 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE T RIGHT PIN18 WIUBE 4 BK PLATFORM CONTROLS A WH BRANE DECAL L19 LED 127 HIGH TORQUE LED L21 E p MEM POUT2 4 4 POWER LED POUT3 p2 POUT4 O 4 FAULT LED 125 POUTS ie ES 4 GENERATOR POUT6 e 06 1 POUT7 O D 4 E 4 LPG LED L22 POUT8 O HIGH IDLE LED 123 PINS a ENGINE STOP BN1 E PING ENGINE START BN2 Ed PIN10 O HIGH IDLE E PIN19 4 HORN BN5 T PIN23 O HIGH TORQUE BN6 PIN24 E GENERATOR
153. 04 4 9400000 6 GLOW PLUG 1 85 86 87 85 87 85 86 87 L30 9 HOURMETER 7 zi DZ g 19 HYDRAULIC OIL TEMPERATURE SWITCH 30 i 87 CR1 ENGINE START m HYDRAULIC OIL pe 25 S COOLING FAN OPTION 9 OPTION HYDRAULIC OIL COOLER a F PLATFORM KS1 6 FUEL SHUT OFF GROUND GROUND m g ENGINE STARTER Ll tn BATTERY 12V DC Diesel Models from serial number 41200 to 41823 Electrical Schematic Part 1 of 3 Section 6 Schematics nin oc t5 ui icm ZT ze T Iz 2 ZO IE oO gt 52302 enie GS 2668 RT GS 3268 RT ATE 6 70 July 2007 Section 6 Schematics Electrical Schematic REV B Diesel Models from serial number 41200 to 41823 Part 2 of 3 P1 EMERGENCY STOP QD4 c i B B D D zn G8 OUTRIGGERS DIAGNOSTIC OPTION OPTION DISPLAY BN44 FUNCTION ENABLE a 156 53 PLATFORM PLATFORM ELI
154. 1 iD lt p S8 2 AXIS LEVEL SENSOR 20 X X 45 oX kX vay X X AX 54 94 m A ET e Y4 8 Y2 Y6 Y5 Y6A Y5A Y1 Y1A Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9 o OD o o oo n gt 4 2 2 5 2 2 2 5 2 2 2 13 38 2 28 3 25 25 5 T f m m m m m m m 5 2 25 25 2 2 2D RO o T 2 T 2 2 2 o9 OD Og o o 9E 2 m 2 a o m 2 2 gt OF OL Om o o m o J 2 lt 2 lt 2 2 2 zz mz mo mg m m m m m ES c m m m g 49 24 22 1 22 D 2 2 5 gt gt gt E 25 m 2 m z KR 8 8 m B RB RF 28 D 5 9 MACHINE SHOWN IN THE STOWED ES7140R POSITION WITH THE POWER OFF enie A TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 75 Section 6 Schematics July 2007 Electrical Schematic Diesel Models from serial number 41824 to GS6803 42381 Part 3 of 3 P2 QD3 EMERGENCY STOP C c L BK POWER TO PLATFORM A A RD POWER TO GROUND B B Lwa eroun opos opoz i D 2 D BL DATA LINK HIGH YL DATALINK LOW DIP PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE
155. 1 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 Two Hydraulic Hose and Fitting Torque Specifications 1 Blockthe 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 AWARNING 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 AWARNING 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 Genie GS 2668 RT GS 3268 RT REVA 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 arod through the pin and twist to remove the pin 10 Repeat steps 7 through 9 for the upper yoke pivot pin 11 Remove
156. 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 Part No 52302 Genie GS 2668 RT GS 3268 RT PLATFORM OVERLOAD COMPONENTS 15 Raise the platform until the position indicator corresponds to the maximum load position of the capacity indicator decal ADANGER 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 ata 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 Section 4 Repair Procedures July 2007 PLATFORM OVERLOAD COMPONENTS Set the pressure switch 16 Using a wrench turn the nut of the platform overload pressure switch out o
157. 15 130 STARTING 1 11 E AID 4 4 hie BE x HIGH IDLE LIGHTS LS24 OF LS25 id B1 2 MAXIMUM f LOADSENSE t e wA 86 30 HEIGHT DELAY i 926 col it j LIMIT SW en 30 9 p 4 1 85 87 i Oy l DOWN 85 87 q Y7A 10 mE spe C5 4 LC 4 gt 4700 uF gy 17 ae t choke 1 103 HX SotENOIDI HIGH IDLE Y8 id Y10 DL 1 4 2 6882 amp i i DS o ES E yo gt lt gt gt n Jd o gt gt os Se d gt m 2 E 4 a d m z 24 g 2 RZ 5 m 9 9 c 96 95 m o 2 D yx I 2 2 5 20 e g d Zz o gt lt od S TI sz 53 5 SB 828568 5 8 4 5 83 5 55 5 55 9 g 2 9 5 m 5 5 m 9 g I Z 2 5 2 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ERES n Genie A TEREX COMPANY 6 46 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Electrical Schematic REV A CE Models with Gasoline LPG Power from serial number GS6805 44169 to GS6805 44770 Part 2
158. 1813 LS14 1815 BN90 1854 BN83 BN84 De LEFT RIGHT LEFT RIGHT CHOKE HIGH PLATFORM PLATFORM o FRONT FRONT REAR REAR IDLE UP DOWN OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER N C 0 EJ 3 o o o o 2 7 1 1 7 1 2 1 ae S7 2 MODELS 9 E A WITHOUT LEVEL LOUTRIGGERS SENSOR gt zz BN 1 2 HIE NN as ZELLE a TS E c by by e o vmm ns P pi gt glee 95 8 1 o y U5 8 8 ELECTRONIC CONTROL MODULE OQ O FFF 4 l d c m c c c c e c c e ez e e c c z i ni 5 lt E BR 8 amp 5 o 3 BR 8 D lt o ifr 58 2 AXIS LEVEL SENSOR Q1 02 X Al x i KCOX X X X 1 I 1 4 ALY zl ray X X X X T x 4 e e s Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 YIA Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9 Q1 M4 Q2 o o 2 w o TU OE OD fe gt T zi 2 2 2 2 2 2 2 m m mc a 22 2 2 8 Z 2 99 91 92 5332 3 5 93 omg n 5 f m m m m m m m 24 25 Zy 2 2 2 6 Qa Q 2 o9 02 Om 9 D D or mec 2 m 2 m m gt gt gt 93 OF Om GB 0 fo m m 2
159. 2 July 2007 Section 2 Specifications REV D Machine Specifications Specifications Rough Terrain foam filled un Tire size Fluid Capacities bef number 42000 us ee before serial number 41200 26 x 12x 12 Hydraulic tank 21 5 gallons after serial number 41199 26 x 12D380 81 4 liters Tire ply rating 8 Hydrauli t including tank 25 gallons ydraulic system including tank gall uvam An 94 6 liters 66 cm Fuel tank 15 gallons 568 liters lire width 12 in 30 cm Fluid Capacities after serial number 41999 Weight 178 165 7 Ibs Hydraulic tank 15 gallons 80 7 kg 3 4 kg 56 8 lit bids Non marking solid rubber Hydrauli t including tank 17 gallons ydraulic system including tank gall Tire size PET E 64 4 liters 55 9 x 40 6 x 22 9 cm Fuel tank 14 5 gallons Aa liters Tire diameter 22 in 55 9 cm Wheel alignment specification dala cba Tire width 9 in Toe in Measurement 0 0 125 inch 22 9 cm 0 3 2 MM Weight 120 Ibs 1 Ibs Tire and wheels 54 4 kg 2 2 kg Wheel lugs 6 Q 1 2 20 Industrial foam filled before serial number 41200 Lug bolt torque dry 90 ft Ibs Tire size 24 12 00 x 12 in 122 Nm Tire ply rating 8 Lug bolt torque lubricated 67 5 ft lbs 91 5 Nm Tire diameter 24 in 61 cm Castle nut torque dry 300 ft lbs 406 7 Nm Tire width 12 30 cm Castle nut torqu
160. 2 AUTO LEVEL BN20 HIGH TORQUE LF OUTRIGGER HIGH IDLE BN4 l LPG SELECT RR OUTRIGGER BN22 HORN LR OUTRIGGER BN15 GENERATOR RF OUTRIGGER BN18 OUTRIGGER ENABLE BN16 STARTING AID BN3 J BK POUT2 E 24 POUT3 Ed POUT4 La 5 POUT6 4 La POUT8 O l V 2 PIN5 8 PIN6 e PIN10 O s PIN19 PIN23 O 22 PIN24 O es T PIN13 O PIN25 O bu PIN25 O 4 me PIN29 O s Wn PIN2 BL ENABLE HIGH BN12 LIFT ENABLE LOW BN13 0 4 O POUT1 RD YE e p DOWN RD BK PIN11 H1 ALARM PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS PLATFORM amp OUTRIGGER UP DOWN TS21 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 25 July 2007 REV 1J4 A2 eX o S GENERATOR OPTION N N N GENERATOR ON LED J4 B6 START ES0116V J4 A1 N J2 B8 ge vj OIL PRESSURE LED 42381 LPG I COOLANT 5 42 2 TEMPERATURE LED BN14 BN68 U5 ELECTRONIC CONTROL MODULE 1
161. 2 Drive reverse Y51 output GS 84 90 B2 Level sensor S8 black input Proportional flow control Y9 output GS 68 Level sensor S8 yellow input B3 Drive forward Y51 output GS 84 90 B4 Plug B4 Proportional flow control Y9 output GS 84 90 B5 Plug B5 Right front outrigger Y36 output Plug B6 Outrigger extend Y40 output B7 Engine start relay CR1 86 output B7 Outrigger retract Y39 output B8 Ignition relay CR8 86 output B8 Outrigger extend slow Y44 output B9 Engine high idle output B9 Left front outrigger Y35 output B10 Level sensor S8 red output B10 Left rear outrigger Y33 output 11 Horn relay CR5 86 output B11 Right rear outrigger Y34 output B12 Alarm output B12 LPG select diesel shutoff output C1 System power input C1 Plug C2 System power input C2 Platform overload input C3 System power input Right front outrigger limit switch LS13 input C4 Engine starting aid output C4 Right rear outrigger limit switch LS12 input C5 Oscillate stowed relay CR84 86 output C5 front outrigger limit switch 1812 input C6 Oscillate raised relay CR85 86 output C6 rear outrigger limit switch 1514 input C7 Ground output C7 Alternator input C8 Plug C8 Engine oil pressure SW2 input C9 Plug C9 Engine water temp SW1 OR oil temp SW3 input C10 Aux down relay CR23 87 output C10 Plug C11 Flashing beacons FS1
162. 2 2 t m D po ud o 5 5 etd et rum im e m 9 J1 PIN4 X 5 m 2 3 2 PLATFORM UP DOWN TS20 E 2 2 gt BL OR o J1PIN3 O o 9 z 8 B N X PLATFORM 8 OUTRIGGER m m D UP DOWN m 2 2 0 80 T BK L E J1 PINS o RD H1 MACHINE SHOWN IN THE STOWED ici POSITION WITH THE POWER OFF ESTIGA enie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 81 Section 6 Schematics July 2007 Electrical Schematic ANSI Models with Diesel Power REVA from serial number GS6805 43595 to GS6805 44770 Part 1 of 3 FQsaruse P emercency stop are ME iKS1 1 PLATFORM i CONTROL l4 31 GROUND CONTROL d 4 ABT CB2 20A 01
163. 2 8 8 B B E 4 2 2 q 9 2 PNIS SYSTEM STATUS 150 2 2 2 m 2 m 2 Q i m g n i J1 PIN4 YL E z m 2 3 7 PLATFORM UP DOWN TS20 5 9 a 6 6 S J1 PINS BL X OR 5 o o m d 5 IAS PLATFORM amp OUTRIGGER m m D UP DOWN m 2 2 BD To L 4 J1 PINS BK H1 MACHINE SHOWN IN THE STOWED ee PLATFORM POSITION WITH THE POWER OFF CONTROLS ES7161A enie A TEREX COMPANY 6 40 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 41 Section 6 Schematics July 2007 Electrical Schematic CE Models with Gasoline LPG Power REV B from serial number GS6805 43595 to GS6805 44168 Part 1 of 3 FOsarust X c P1emerceNcy stop premens IKS1 KEY
164. 2 way 9 50 2 gpm 12V DC with diode schematic items U W X and Y 7 5 L min Solenoid valve 2 position 2 way 90 12V DC with diode schematic item AI 2 psi Solenoid valve 2 position 2 way 7 50 37 8 12V DC schematic item Solenoid valve 3 position 4 way 7 50 3000 12V DC schematic item BD 206 8 bar Solenoid valve 2 position 2 way 8 20 4 5 gpm 10V DC schematic items CA CB CC and CD 17 Limin Solenoid valve 2 position 3 way 60 12V DC schematic item DA 28 3cuin Continuous improvement of our products is 464cc Genie policy Product specifications are subject to change without notice Genie GS 2668 GS 3268 RT 2 3 Section 2 Specifications July 2007 SPECIFICATIONS Kubota D905 Engine before serial number GS6805 43886 Displacement 54 86 cu in 0 90 liters Number of cylinders 3 Bore and stroke 2 83 x 2 90 inches 72 x 73 6 mm Horsepower gross intermittent 26 3600 rpm 19 3 kW Firing order 1 2 3 Compression ratio 23 1 Compression pressure 412 to 469 psi 28 4 to 32 3 bar Low idle 1500 rpm 300 hz High idle 3000 rpm 600 hz Governor centrifugal mechanical 0 0057 to 0 0072 in 0 145 to 0 185 mm Valve clearance cold Engine coolant capacity 3 3 quarts 3 1 liters Lubrication system Oil pressure 36 to 64 psi 2 48 to 4 41 bar Oil capacity including filter 5 4 quarts 5 1 liters Cil viscosity requirements Units ship with 15W 40 Extreme operating temperatu
165. 23 91 J2 C4 0 AUXILIARY DOWN AUXILIARY DOWN J2 B9 ENABLE CR15 13 5 5 STARTING 30 AID WORK ABS 8 HIGH IDLE LIGHTS n c RET 86 30 4 LS24 OF LS25 lt B1 wi uta 30 8 MAXIMUM LOADSENSE P t deu AE aros m 85 87 FA PE 4 7 CR77 52 4 a Dom et 4 10 E C5 51 Q8 U32 aou 1 FUEL GLOW 8 SHUT S PLUG HX OPTION 8 AE HIGH IDLE Y8 i YT Y10 SOLENOID 1 io 4 i 4 1 1 4 4 s 8 8 8 8 8382 S gt o 0 m 2 I m T gt 09 n o 5 z z gt lt gt gt m o o A gt 55 oe Q Q a d D 2 9 2 z m BS 5 z x v E x 5 m m o o m mom gt E I 2 2 5 20 21 gt zi E S m o 5 65 L 5 lt m c I o d sz 53 1 2 amp P 5 8 5 575 2 lt m lt 3 5 2 lt lt m 3 z o m 2 5 o v o o 2 2 5 2 2 MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7184C n Genie A TEREX COMPANY 6 94 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics REVA Electrical Schematic CE Models with Diesel Power from serial number GS6805 44169 to GS6805 44770 Part 2 of 3 CR8 TERMIN BATTERY H
166. 25 GENERATOR LED L27 HIGH TORQUE LED 121 LPG LED L22 HIGH IDLE LED 123 ENGINE STOP BN1 ENGINE START BN2 AUTO LEVEL BN20 HIGH TORQUE LF OUTRIGGER HIGH IDLE BN4 l LPG SELECT RR OUTRIGGER BN22 HORN LR OUTRIGGER BN15 GENERATOR RF OUTRIGGER BN18 OUTRIGGER ENABLE BN16 STARTING AID BN3 J BK POUT2 E 24 POUT3 Ed POUT4 La 5 POUT6 4 La POUT8 O l V 2 PIN5 8 PIN6 e PIN10 O s PIN19 PIN23 O 22 PIN24 O es T PIN13 O PIN25 O bu PIN25 O 4 me PIN29 O s Wn PIN2 BL ENABLE HIGH BN12 LIFT ENABLE LOW BN13 0 4 O POUT1 RD YE e p DOWN RD BK PIN11 H1 ALARM PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS PLATFORM amp OUTRIGGER UP DOWN TS21 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 17 July 2007 Section 6 Schematics Electrical Schematic REV Gasoline LPG Models from serial number 38465 to 41199 Part 1 of 3 P1 EMERGENCY CB2 STOP C
167. 2668 RT GS 3268 RT REV 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 AWARNING 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 AWARNING outer arm index 4 at the engine side could become unbalanced and fall if not properly supported when removed from the machine Part No 523
168. 39 E 1749 1477 s 312 60 908 890 1206 1080 1464 1440 1962 1220 1654 D 2074 a a 1 1260 1240 1681 1510 2047 2010 2755 1700 2304 Koree 3620 150 2067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual i 5 Class 8 8 Class 10 9 03 Class 12 9 DRY ssa 68 775 91 105 15 DRY DRY 458 622 612 830 583 791 778 1055 682 925 909 1233 94 7 82 7 108 4 149 162 142 203 176 230 189 281 244 325 271 515 133 569 474 827 591 ofl a N oa o 108 4 122 162 176 217 244 110 120 150 170 210 240 380 420 Poy oa c i ile c m ile ER m 4 3 435 D 0 A yof O1 CO ala cal EN D 4 18 ile o D o 00 N zik lo a A Go 53 AB 2 2 CO OV CF Do ca 9 A c es Bl 3 B lt r c B r c 0 i NI BR Oy OY 0 oj A Oo NIK 99 NIS BAIN ges CO N Oo A co Cf ON
169. 4 FAULT LED 125 POUTS ie ES 4 GENERATOR POUT6 e 06 1 POUT7 O D 4 E 4 LPG LED L22 POUT8 O HIGH IDLE LED 123 PINS a ENGINE STOP BN1 E PING ENGINE START BN2 Ed PIN10 O HIGH IDLE E PIN19 4 HORN BN5 T PIN23 O HIGH TORQUE BN6 PIN24 E GENERATOR BN7 JE PIN13 O LPG SELECT BN14 E PIN25 O PLATFORM EXT RET ENABLE BN16 T PIN29 4 STARTING AID RD BL PINs 9 DOWN POUT1 PIN11 O H1 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 6 16 WH GROUND BK POWER TO PLATFORM RD POWER TO GROUND REV P2 EMERGENCY a STOP BL DATA LINK HIGH YL LOW enie A TEREX COMPANY PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR 15 JOYSTICK 246 9 5K CONTROLLER MS POTENTIOMETER PP 8 WH BK WH YL 50 5 FUNCTION ENABLE T VBL 5 2 0 bd PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 LIFT ERROR INDICATOR LED L57 FAULT LED L
170. 5 z d 79 6 z o m o o D T z o z 2 2 z B gt z MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Genie A TEREX COMPANY 6 82 GS 2668 GS 3268 RT Part No 52302 July 2007 Section 6 Schematics REVA Electrical Schematic ANSI Models with Diesel Power from serial number GS6805 43595 to GS6805 44770 Part 2 of 3 CR8 TERMINAL 30 BATTERY 4 8 aid 25 iC ME 4 30 88 Ux CR17 wd HYDRAULIC 112 OILCOOLER A e OPTION LEVEL 57 SENSOR A 1 MODELS WITHOUT BATTERY p QUTRIGGERS 823 855 ABI t rs c gt uU N a U5 7 ELECTRONIC CONTROL MODULE 5 5 f 525 4 5 5 gt gt 9 9 N 5 o zi N E 5 5 8 9 22 ABTS 4 n YA Y1 Y1B Y6 Y6A Y9 gt A Al 1 Mr Q EX 1 1 SW2 SW1 5 FB1 Y1A Y2 Y5 Y5A Y29 4 4 4 4 n 4 n Q X T lt lt lt lt lt lt lt lt lt lt lt lt m e 82 EP am 06 4 9
171. 5666 3241 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 Service Manual GS 2668 RTeGS 3268 RT from serial number 101 to GS6805 44770 Part No 52302 Rev F A TERI QIR
172. 57044 HS0027J Genio Part No 52302 GS 2668 RT GS 3268 RT 6 101 Section 6 Schematics July 2007 Hydraulic Schematic from serial number 35557 to 40484 REV B Part 1 of 2 OUTRIGGERS GENERATOR OPTION OPTION GENERATOR A A T MANIFOLD Y29 i O ES RIGHT 000 psi EA FRONT FRONT 206 8 OUTRIGGER OUTRIGGER g at b o 1 __ OUT B MCN 742 7177 5 773207572 ourriacer STEER CYLINDER MANIFOLD i 4 1 D LEFT faoa 2 71207 bar 1 URSI ECCE REAR LEFT REAR OUTRIGGER inm m JANT I 0 063 in 99 eU OO 1 6 mm KO 40 X4 LL 1 Y39 dee x 68 1 103 4 bar 2000051 e 137 8 bar IN OUT Tue ue a ear 692282355065
173. 595 to GS6805 44168 Part 2 of 3 f CR8 TERMINAL 30 ABZ BATTERY z e Hf SWA 20 Jiu uie SE 1 CR17 s qe o HYDRAULIC OILCOOLER ipd 57 on d MODELS WITHOUT BATTERY QUTRIGGERS Sza BK 1 29 6 U5 5 ELECTRONIC CONTROL MODULE YA Y1 Y1B Y6 Y6A Y9 4 X EX DZ O X EFX X NE SW ped Y1A Y2 Y5 Y5A Y29 6 55 505 25 85 id B 9 9 23 o 2 2 2 5 m gt E m 2 E y T D 9 m T 2 85 2 3 9 2 35 3 2 9 D 45 S d 3 Eg E 2 BZ 7 205 5 eea eer 5 50 2 S 7 S 5 9 S 2 g E g NOTE MACHINE SHOWN IN THE STOWED ES7184B POSITION WITH THE POWER OFF Genie Part No 52302 A TEREX COMPANY GS 2668 RT GS 3268 RT Section 6 Schematics July 2007 Electrical Schematic CE Models with Diesel Power from serial number GS6805 43595 to GS6805 44168 Part 3 of 3 REV B
174. 68 RT Part No 52302 July 2007 Section 4 Repair Procedures REV D 9 3 Outrigger Manifold Components The outrigger manifold is located beneath the hose cover panel on top of the drive chassis Index No 1 2 3 Schematic Description Item Function Relief valve 2000 psi 137 8 bar BA Outrigger circuit Solenoid valve 2 position 2 way BB Outrigger slow extend Orifice plug 0 063 inch 1 6 mm ee BG uus Outrigger retract Solenoid valve 3 position 4 way Outrigger extend retract Counterbalance valve not used after serial number 40484 BE Outrigger retract circuit 0 MANIFOLDS Torque 20 ft lbs 27 1 Nm 25 ft lbs 34 Nm 25 ft lbs 34 Nm 30 35 ft lbs 41 47 Nm C Oo gt er Genie MR Part No 52302 GS 2668 RT GS 3268 RT Section 4 Repair Procedures July 2007 MANIFOLDS 9 4 Valve Adjustments Outrigger Manifold How to Adjust the Outrigger Relief Valve AWARNING 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 a
175. 68 RT 4 73 Section 4 Repair Procedures July 2007 MANIFOLDS REV D Function Manifold Components continued Index Schematic No Description Item Function Torque 14 Check valve etes Drive circuit anti cavitation 20 25 ft lbs 27 34 Nm 15 Relief valve 3500 psi 241 3 bar Quis Relief valve for number two section of pump 15 25 ft lbs 20 34 Nm 16 Solenoid valve 2 position 4 way Platform tees 25 30 ft lbs 34 41 Nm 17 Priority flow regulator 2 gpm 7 6 L mln eee Qus Steer circ il s 25 30 ft lbs 34 41 Nm 18 Solenoid valve 3 position 4 way sider ence Steer left right 25 30 ft lbs 34 41 Nm 19 Orifice plug 0 035 0 89 mm Suus Brake circuit 20 Proportional solenoid valve N O T ains Drivej lift circult 5 25 30 ft lbs 34 41 Nm 21 Solenoid valve 2 position 2 way Ro Brake GIU 20 25 ft lbs 27 34 Nm 22 Relief valve 1500 psi 103 4 bar Steer left right 25 30 ft lbs 34 41 Nm 23 Solenoid valve 2 position 2 way POPPE icio eere ees W Drive speed select circuit 25 30 ft lbs 34 41 Nm 24 Solenoid valve 2 position 2 way N O ipoppet edes gt Drive speed select circuit
176. 68 RT 567 kg GS 3268 RT 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 Part No 52302 July 2007 Section 4 Repair Procedures EE REV B PLATFORM OVERLOAD COMPONENTS 26 Raise the platform in 5 cm increments until the 27 Install and adjust the maximum height limit overload alarm sounds and the engine stops switch until it activates just before the point running Proceed to step 27 reached in step 26 Securely tighten the f D ighten Result The alarm does not sound and the engine continues to run when the platform 28 Use the auxiliary down function to lower the reaches full height Repeat this procedure platform approximately 15 cm D WI Steps 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 funct
177. 7 Raise the platform at least 12 feet 3 6 m Result ANSI and CSA models The tilt alarm will sound at 180 beeps per minute O Result CE and Australian models The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted After serial number 41136 Raise the platform at least 12 feet 3 6 m Result The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS 52 Lower the platform to the stowed position 53 Push in the red Emergency Stop button to the off position at both the ground and platform controls 54 Turn the key switch to the off position 55 Raise the machine slightly 56 Remove the blocks from under both wheels 57 Lower the machine and remove the jack 58 Before serial number 41200 Close the ground control panel Install and securely tighten the retaining fasteners Do not over tighten After serial number 41199 Install the cover onto the level sensor enclosure Install and securely tigh
178. 7 U5 2 8 Poure Ed qo HIGH TORQUE LED L21 ELECTRONIC CONTROL MODULE POUT8 4 HIGH IDLE LED L23 4 amp S F Fig 7 gt 0 gt 5 gt 8 amp amp 3 8 PS PIN5 4 4 ENGINE STOP BN1 PING e ENGINE START BN2 A 0 4 4 HIGH IDLE BN4 E 1 pmo 4 HORN BN5 EJ PIN 4 4 HIGH TORQUE BN6 LT 1 d 1 PIN24 O e GENERATOR BN7 X AL X X 2 PIN25 O ta PLATFORM EXT RET ENABLE BN16 PIN29 O ES 4 STARTING AID BN3 1 Mis 1 ES AI x fi X PIN13 4 4 LPG SELECT BN14 o e 4 LIFT ENABLE HIGH BN12 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y9 BL EN o v PIN2 LIFT ENABLE LOW BN13 do md E 32 nx X 2 2 2 2 52 m m B 2 lt lt lt lt lt 9 PINs 0 2 22 5 m TT T D X uw o9 A PLATFORM UP DOWN TS20 2 h 2 6 gt 3 gt OB O m m m E D D 2 gt 3 7 g n g 8 g 8 E E gt 429 gt gt gt ec r os POUT 8 8 R BR B B RB P 2 8 PIN11 ES0116G OSITIO OWER enie A TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 13 STOP P1 EMERGENCY REV July 2007 CB2 1A E CB2 CHANGED TO 7 AMP AFTER SERIAL NUMBER
179. 7 Section Scheduled Maintenance Procedures REV D CHECKLIST B PROCEDURES B 3 B 4 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 Checkthe 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 Part No 52302 Genie GS 2668 RT GS 3268 RT Perform Engine Maintenance Perkins 403C 11 Models Engine specifications require that this procedure be performed every 250 hours or six months whichever comes first Required maintenance procedures and additional engine information is available in the Perkins 403C 11 User s Handbook Perkins part number 100816460 Perkins 403C 11 User s Handboo
180. 8 9 L Ji 7 d dos 2900 oi 193 bar FUNCTION rc bar MANIFOLD ee NEST E SENE IE 57044 HS0027L Genio Part No 52302 GS 2668 RT GS 3268 RT 6 107 Section 6 Schematics July 2007 M Hydraulic Schematic from serial number GS6804 43184 to GS6805 44770 REV B Part 1 of 2 GENERATOR OPTION i pv E 69 GENERATOR OUTRIGGERS MANIFOLD OPTION zl DB 4 5 LEFT FRONT RIGHT FRONT i 17 OUTRIGGER OUTRIGGER 12068 I 5 CB J MMC dae a q OF j 9v pr PM STEER CYLINDER 5 OO Qurh TEST1 TEST2 Lemn X va Y40 X IIH i Y39 R n 69 vi OUTRIGGER O NE 9 e MANIFOLD 1 x get our 1 I i500 psi EIL 12 1 103 4 bar ex ir RE EET 1 Ica gt b
181. 8 d PN gt LPG SELECT BN14 Y36 Y34 Y40 Y44 T d o Vj rne 3 LF OUTRIGGER ENABLE BN85 Poo RF OUTRIGGER ENABLE BN86 A X X 2 M CQ Li BA PIN LR OUTRIGGER ENABLE BN87 Y35 Y33 Y39 RR OUTRIGGER ENABLE BN24 4 4 4 Be 8 x NR ge 5 E LIFT FUNCTION BN9 2 2 gt Db NAE 9 a 5 g S amp PIN14 O 4 ORGR AUTOLEVEL ENABLE BN20 3 3 3 8 B 2 E m 2 gt D 5 m m o o o PIN15 SYSTEM STATUS 150 2 gt m m m m m 2 4 mil 2 2 2 t m D po ud o 5 5 etd et rum im e m 9 J1 PIN4 X 5 m 2 3 2 PLATFORM UP DOWN TS20 E 2 2 gt BL OR o J1PIN3 O o 9 z 8 B N X PLATFORM 8 OUTRIGGER m m D UP DOWN m 2 2 0 80 T BK L E J1 PINS o RD H1 MACHINE SHOWN IN THE STOWED ici POSITION WITH THE POWER OFF easton enie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 85 Section 6 Schematics July 2007 Electrical Schematic CE Models with Diesel Power REV B from serial number GS6803 42382 to GS6805 43594 Part 1 of 3
182. 8 5 o 9 X 5 9 9 NOTE ES7184C Part No 52302 Genie bebe MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF GS 2668 RT GS 3268 RT Section 6 Schematics July 2007 Electrical Schematic CE Models with Diesel Power from serial number GS6805 44169 to GS6805 44770 Part 3 of 3 REVA CENE CN 004 QD3 P2 EMERGENCY WHIRD 4 4 4 BK POWER PLATFORM STOP RD WH Rb POWER ro GROUND 31 BL 1 iH 1 1 WH GROUND 2 25 2 2 BL DATALINK HIGH OR 5 5 H 5 5 OR DATA LINK LOW jesse a 3 OUTRIGGERS OPTION J5 PIN2 2 gt eo PCS D7 ABS ABS PLATFORM CONTROLS VOLTAGE zy pc PRINTED CIRCUIT BOARD REGULATOR 2 AXIS TILT LEVEL J2 PIN1 SENSOR m A
183. 8 F m 2 m o a 3 9 5 4 5 3 ov 9 9 5 3 o Z 9 MACHINE SHOWN IN THE S POSITION WITH THE POWER OFF Genie Part No 52302 A TEREX COMPANY GS 2668 RT GS 3268 RT Section 6 Schematics July 2007 Electrical Schematic CE Models with Gasoline LPG Power REV B from serial number GS6803 42382 to GS6805 43594 Part 3 of 3 2251225 904 QD3 WHIRD 4 4 1 4 4 BK POWER TO PLATFORM RD WH 3 7 Rb POWER GROUND f 0 BL 1 1 1 1 H WH GROUND BK i 2 2 2 2 BL DATALINK HIGH OR 5 5 T 5 5 1 OR DATA LINK LOW OUTRIGGERS OPTION J5 PIN2 2 2 D7 PLATFORM CONTROLS VOLTAGE sy pc PRINTED CIRCUIT BOARD REGULATOR 2 AXIS TILT LEVEL J2 PIN1 SENSOR jo PIND YL 41 HALL EFFECT 2 WH 7s GENERATOR JO
184. 9 Genie part number 84250 Kubota DF750 Workshop Manual Kubota DF752 Workshop Manual Genie part number 52492 Genie part number 84249 Genie GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV C 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 Startthe 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 Part No 52302 Genie GS 2668 RT GS 3268 RT 4 39 KUBOTA DF750 DF752 ENGINE Solenoid boot threaded rod yoke locknut 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
185. 93 Section 6 Schematics July 2007 p M Electrical Schematic CE Models with Diesel Power REV A from serial number GS6805 44169 to GS6805 44770 Part 1 of 3 FQsaruse P1emerGeNcy KEY SWITCH 4 ss 1 I I oT os PLATFORM CONTROL T P S 2A PLATFORM OVERLOAD PRESSURE SWITCH 14 4141 a R25 d 5 OHM 3 GROUND CONTROL 1 20 CB2 20a 1 e aBa nes 28 CR41 CR1 CR23 G6 NC CONTROL CR42 CR5 CR8 ENGINE AUXILIARY HOUR 1 SYSTEM POWER HORN IGNITION START DOWN 27 LS6 PLAT 86 N 86 2 86 2 86 ad 4 86 2 86 DOWN SEL T 85 85 85 85 85 SWITCH 4 4 n HHS em 88282 S268 8 9 CN RR d pce atc BN
186. AR REAR CHOKE ATE PLATFORM T a OUTRIGGER f OUTRIGGER E SENSOR BOARD i o o gy 8 i t E NO 3 mn S7 5 WITHOUT LEVEL gt gt OUTRIGGERS SENSOR Ble meme SENSOR BN m cs xiu TE oum m Qoo 5 vmm 8 S 628 amp 2 amp 8 9 5 LB 3 9 U5 9 ELECTRONIC CONTROLMODULE sss ____ amp d Bono x l 5 5 5 5 i F F 5 t 4 E 8 5 8 5 3 s 8 9 8 sas 2 S 1 D lt P S8 2 AXIS LEVEL SENSOR Q1 Q2 4 AL X aK X X X 1 z eX EX X X X n 4 4 4 4 4 Y4 Y8 Y2 Y6 Y5 Y6A Y1 Y1A Y9 Y35 Y36 Y33 Y34 Y40 Y39 Y44 S9 Q1 M4 Q2 o0 0 23 90 g AD gt d m b 2 2 2 2 2 2 2 2 021 61 69 61 58 05 54 8 m5 T T d A m m m m mM m gt BI 24 2 BO Qo TO x X T 2 m 2 T 09 93 Om Q Q Q m 2 2 2 od OD gt 0 0 0 2 2 o m J 23 lt 2 2 D zd m9 m gt m m m m 5 x 3 3 m gt gt gt 39 22 1 05 D D D E E 2 2 22 m 6 3 D 5 29 h
187. BLE T _ TS66 9 BOARD PIN18 5 5 8 i id O LWH RD 5 E S7 WH gt 5 2 LEVEL L 4 E SENSOR MEME i ME PLATFORM CONTROLS BN MEMBRANE DECAL Pour POWER LED L19 pours M S i 5 PES BOB 5 B B POUT4 Ly FAULT LED L25 5 QE EE 5 2 9 POUTS o 4 GENERATOR LED 127 U5 2 8 Poure Ed qo HIGH TORQUE LED L21 ELECTRONIC CONTROL MODULE POUT8 4 HIGH IDLE LED L23 4 S F 9 1 7 m m 1 1 1 1 gt gt 2 D gt 8 g g o 3 B8 PS PIN5 4 4 ENGINE STOP BN1 PING e ENGINE START BN2 A 0 0 4 4 HIGH IDLE BN4 E 1 pmo 4 HORN BN5 PIN9 4 4 HIGH TORQUE BN6 LT 1 1 d 1 PIN24 O e GENERATOR BN7 X AL X X PIN25 O tet PLATFORM EXT RET ENABLE BN16 PIN29 O so 4 STARTING AID BN3 1 1 1 1 aX AI 42 2 X X LIFT ENABLE HIGH BN12 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y9 o v PIN2 LIFT ENABLE LOW BN13 do md E 32 nx X 2 2 2 2 52 m m B 2 lt lt lt lt lt 9 PINs 0 2 J m m Hi m yL PLATFORM UP DOWN TS20 2 5h 2 6 gn 9 gt GB 0 1 o 1 2 lt 2 lt 2 2 zd 5 cb
188. BN2 A 4 HIGH IDLE BN4 E PIN19 O 4 HORN BN5 PIN9 4 4 HIGH TORQUE BN6 LT 1 1 d 1 PIN24 O e GENERATOR BN7 X AL X X PIN25 O tet PLATFORM EXT RET ENABLE BN16 PIN29 O so 4 STARTING AID BN3 1 1 1 1 kay 2 X X n LIFT ENABLE HIGH BN12 Y4 Y8 Y2 Y6 Y5 Y6A Y5A Y1 YIA Y9 o v wo o c o mo PIN2 LIFT ENABLE LOW BN13 dod 32 nx X 2 2 2 2 52 m m 2 lt lt lt lt 9 PINs 0 mo cu ms du 555 A PLATFORM UP DOWN TS20 2 5h 2 6 mn 9 gt gt GB 0 1 o 1 2 lt 2 lt 2 2 zd i g oue ge 39 gt r o os POUT 8 8 R BR B B m P PIN11 ES7140B POSITION WITH THE POWER OFF enie Part No 52302 A TEREX COMPANY GS 2668 RT GS 3268 RT Section 6 Schematics July 2007 Electrical Schematic Diesel Models from serial number 21838 to 38464 REV B Part 1 of 3 CB2 CHANGED 7 P1 AFTER SERIAL NUM 01 EMERGENCY BER 3385 STOP
189. BN7 JE PIN13 O LPG SELECT BN14 E PIN25 O PLATFORM EXT RET ENABLE BN16 T PIN29 4 STARTING AID RD BL PINs 9 DOWN POUT1 PIN11 O H1 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 WH GROUND BK POWER TO PLATFORM RD POWER TO GROUND REV P2 EMERGENCY a STOP BL DATA LINK HIGH YL LOW enie A TEREX COMPANY PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR 15 JOYSTICK 246 9 5K CONTROLLER MS POTENTIOMETER PP 8 WH BK WH YL 50 5 FUNCTION ENABLE T VBL 5 2 0 bd PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 LIFT ERROR INDICATOR LED L57 FAULT LED L25 GENERATOR LED L27 HIGH TORQUE LED 121 LPG LED L22 HIGH IDLE LED 123 ENGINE STOP BN1 ENGINE START BN2 AUTO LEVEL BN20 HIGH TORQUE LF OUTRIGGER HIGH IDLE BN4 l LPG SELECT RR OUTRIGGER BN22 HORN LR OUTR
190. Be IO 688 m 8 Sg Lu ga l HeNi a z J2 B10 J2 A6 J2 C1 C10 3 DATA LINK YL J2 B3 LY O E Ja a5s 1 9283 225 AUTO LEVELING Iz DATAUNK BK a4 J2 B1 35 SENSOR TA 7 adu 2 GROUND FROM PLATFORM j3 g 2 810 m OUTRIGGER EXTEND z d gt SLOW J3 B5 J1 B7 OUTRIGGER RETRACT lt Q gt E 9 0 2 Q E J1 B6 OUTRIGGER EXTEND E 1 B e ANT d xs RIGHT REAR 188 5 B OUTRIGGER d 5 gt lt LEFT REAR 2 18 OUTRIGGER ro EER T 5 8 nomino D gt s 2 o gt lt 19 LEFT FRONT J2 A8 9 T5 A Pal D TS OUTRIGGER gt M E z p 8 l gt lt 4 9 PROPORTIONAL gt FLOW CONTROL l gt K m 2 4 J2 A7 J1 A12 thi DRIVE PARALLEL 8 gt i 0658 6 Dd amp ig 2 lt 1 6 su JI AT t Rar DRIVE PARALLEL 28 a JI A10 to 422 DRIVE PARALLEL lt fa fences due J1 A8 tH 12 DRIVE REVERSE 5 ki J9 A3 7 55 di lt 328 Noe 2 J1 A7 tor DRIVE FORWARD 2278 2 gt E 1408 u ui mu J3 A1 _ ite ERE m
191. 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 Section 4 Repair Procedures July 2007 GROUND CONTROLS 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 Pressthe 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 FO DO and lower Use the yellow platform down arrow to scroll to lift drive cutout Result CUTOUT is showing in the diagnostic display window Wi Result LFr bRv cutout orr 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 position 7 Usethe yellow platform down arrow to scroll to motion alarm Result ALARM is showing in the diagnostic display window 8 Pressthe 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 diagnost
192. C 11 User s Handbook Kubota DF750 Operator s Manual Genie part number 97360 Genie part number 97359 Kubota DF752 Operator s Manual Genie part number 84250 Genie GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 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 M 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 Part No 52302 Genie GS 2668 RT GS 3268 RT 4 1 Repair Procedures Ab
193. C1 C4 8 8 8 8 O c TA D bc ic H i on r gy AUTOMOTIVE STYLE HORN 5 s S s ADEM ZEN S5 I OPTION e N HIGH IDLE SOLENOID OO 62 0000016 GLOW PLUG 2 0000012 4 4 s 4 58 HOURMETER TT z Ot d c 8 LL L Or ME 1 oo LLI O amp FUEL SHUT OFF pa ee qna 2 mz oie ALTERNATOR e N Jiii ME used 3 5 s Ke gt Iz g E g S ENGINE STARTER 0 2 gt a c M x 9 5 al 2 m lt TE 5652 95 5 BATTERY 12V DC 2488 5 ES LT 58 gt 52302 enie GS 2668 RT GS 3268 RT ATE 6 52 July 2007 Section 6 Schematics REV B Electrical Schematic Diesel Models from serial number 21161 to 21837 Part 2 of 2 P2 EMERGENCY QD
194. Coolant Temperature and Oil Pressure Switches 4 41 D Ground Controls 7 1 Auxiliary Platform Lowering een 4 42 7 2 Function Speed Tuning from serial number GS6803 42382 to GS6805 44770 4 48 7 3 Software Configuration from serial number GS6803 42382 to GS6805 44770 4 51 7 4 Level Sensor Models without Outriggers before serial number 41754 4 56 7 5 Level Sensor Models without Outriggers after serial number 41753 4 62 7 6 Level Sensor Models with 4 65 A Hydraulic Pump 9 1 teat dee eva cR ug ee 4 70 Genie Part No 52302 GS 2668 GS 3268 RT xi July 2007 SSS SSS TABLE OF CONTENTS Section 4 Rev Repair Procedures continued D Manifolds 9 1 Function Manifold Components 4 72 9 2 Valve Adjustments Function Manifold 4 76 9 3 Outrigger Manifold 4 79 9 4 Valve Adjustments Outrigger 4 80 9 5 Generator Manifold Components 4 82 9 6 Valve Adjustments Generator Manifold 4 83 9 7 4 84 B Fuel and Hydraulic Tanks jS E 4 86 10 2 Hydraulic Frank eet etta ete ete teo rer Rein 4 87 A Steer Axle Co
195. DC i 2298 9 OR cce FA ma 0 La gt A 6 50 July 2007 Section 6 Schematics REV B Electrical Schematic Diesel Models before serial number 21161 Part 2 of 2 P2 EMERGENCY QD 4 QD3 STOP BK ES C BK POWER TO PLATFORM A A A A RD POWER TO GROUND B B B B WH GROUND D D 7 D D 4 BL DATA LINK HIGH E E G8 i YL DATA LINK LOW DIAGNOSTIC fee DISPLAY DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR s piles eps eee oe eee Gia oes ek 7 11 MIT a SS memi ENABLE JC1 5 5 y R15 JOYSTICK LS6 LS5 LS1 tne ene 5K CONTROLLER PLATFORM PLATFORM EXTENSION 2 F 7 OR POTENTIOMETER DOWN 9 UP DECK 8 WH BK WH YL LEVEL STEER i i SENSOR SW5 SW6 LEFT RIGHT N C N C N C o CIRCUIT WH BL FUNCTION ENA
196. E HALL EFFECT GENERATOR v 3 J2PINi2 o JOYSTICK 1512 1513115141515 3 8 BN CONTROLLER n0 9 42 PIN13 LF RF LR RR O RIG O RIG O RIG J2 PINS LIMT UMT UMT gt o lt o JAPIN SWITCH SWITCH SWITCH SWITCH O ess GY J5PIN3 O j SW5 SW6 NOS 2 datos OR FUNCTION ENABLE 2 E 2 STEER 4 2 x BK i 2 LEFT RIGHT 2 AB23 24 J2 PING gt J2 PIN7 BD AB27 AB26 16 Tasas J2 PIN8 1 J2 PIN14 c c c c c c c c C T T T 7 Pp P N ms DNI 9 2 9 92 2 8 8 i z l POUTI PIN2 HORN BN5 U5 PIN3 STARTING AID BN3 ELECTRONIC CONTROL PIN4 ENGINE START BN2 c E e 65 MODULE T wo T T ti a 5 PINS HIGH TORQUE BN6 dc ME MM lasi 6 GENERATOR BN7 qase 7 ABS PIN7 s LPG SELECT BN14 NE a Ape PINS Y36 Y34 Y40 44 1 4 4 n NM C Al X A AC 1 1 I PINS LF OUTRIGGER ENABLE BN85 000 i i 120000000000 Nt 0 RF OUTRIGGER ENABLE BN86 ACOX EE E o LR OUTRIGGER ENABLE BN87 Y35 PIN12 O RR OUTRIGGER ENABLE BN24 i i uu 5 amp x x gi Zw 8 8 8 5 n PIN13 O LIFT FUNCTION BN9 m m o CN OL 2 25
197. E SPEEDS is showing in the diagnostic display window The ECM is now in programming mode 5 Pressthe lift function enable button 6 Use the yellow platform down arrow to scroll to max high speed drive Result HIGH SPEED DRIVE is showing in the diagnostic display window 7 Pressthe 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 9 Press the lift function enable button 10 Push in the red Emergency Stop button to the off position at the ground controls 11 Check the stowed drive speed of the machine Refer to the Maintenance procedure B 10 Test the Drive Speed Stowed Position Part No 52302 July 2007 Section 4 Repair Procedures REV D Models with software revision or higher 1 Pull out the red Emergency Stop button to the on position at the platform controls 2 Pushin 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
198. Electronic Control Module J1 J2 S Generator Et lt Ne gt Outriggers and manifold lt 9 9 KS Ce REVA Platform controls Down limit switch around controls and ECM Genie 6 4 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics ra eee LLL LI XL LL LM Electronic Control Module Pin Out Legend REVA from serial number GS6803 42382 to GS6805 44770 J1 Connector J2 Connector 36 pin 36 pin A1 Right turn output Up limit switch 185 input A2 Left turn Y4 output A2 Down limit switchLS6 input Platform up Y8 output Aux down power input 4 Y2 output A4 Aux down relay CR23 86 output 5 Drive forward 1 Y6 output A5 Key switch KS1 3 input Drive reverse 1 Y5 output Level sensor S7 white input A7 Drive forward 2 Y6A output A7 Plug 8 Drive reverse 2 Y5A output A8 Plug A9 Platform down Y7 output A9 Plug A10 Drive coil Y1 output A10 Platform controls ground input A11 Drive coil Y1A output A11 Platform controls data high input A12 Drive coil Y1B output A12 Platform controls data low input B1 Generator Y29 output B1 Level sensor 58 blue input B
199. F enie A TEREX COMPANY Part No 52302 GS 2668 RT GS 3268 RT 6 11 July 2007 Section 6 Schematics Electrical Schematic REV Gasoline LPG Models from serial number 21161 to 21837 Part 1 of 2 gt i Ep dM J4 c2l 49 LPG SELECT D Ee REC 189 8 4 4 HIGH IDLE 5 N TS54 M A8 19 2 J4 B6 au 4 7556 S 4 mx 5 l o J2 B8 START y T O CM 3 4 J2 A5 g veer c 9 3 J4 B5 Zag J1 011 C12 o J4 C4 X 2 E 5 J4 C3 92 812 J4 B4 T us J1 B1 O n P 2 o yd 02 INT 1 az rE 4 GEB gt og Onz Ji A9 TN 4 Irene o o PI 8 8 g s 8 BET ENDE E E 4 F F 4 Eu aed E T a ic P D i RE Te E 8 s 8 e s s s ss o e 4 8 OS if 4 4 4 Zk V 8 ii 4 SUM S E 2 18 115 gt lt 8 PNE m jm 122732 2 5 ee x 5 8 2 r S 1 N gt 8 E z ce sal xo T zE R m lt 52 S354 OS putes g x A
200. FORM COMPONENTS 11 Position a forklift at the steer end of the machine with the forks even with the bottom of the platform extension 12 Carefully slide the platform extension out until the platform extension makes contact with the carriage on the forklift 13 Attach a lifting strap from the platform extension railings to the carriage on the forklift to support the platform extension 14 Carefully slide the platform extension out and away from the platform and place it on a structure capable of supporting it Crushing hazard The platform AWARNING extension will become unbalanced and fall when removed from the machine if not properly supported and secured to the forklift 4 16 GS 2668 RT GS 3268 RT Genio Meer REVA Part No 52302 July 2007 Section 4 Repair Procedures eee This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 4 17 Section 4 Repair Procedures July 2007 Scissor Components D XS CRO C9 REVC S 2 9 9 2 5 5 2668 N 029 C 9 N Non steer c 10 11 12 Number 5 pivot pin steer end Number 4 center pivot pin Number 4 pivot pin steer end Number 3 out
201. FROM PLATFORM j3 g 22810 m l 3 OUTRIGGER EXTEND z D gt SLOW I D j J3 B5 J1 B7 N 8 OUTRIGGER RETRACT lt T 4 4 T D gt sa Hers 9 gt lt d 3 z 7 86 N X OUTRIGGER EXTEND o xd xs RIGHT REAR 188 OUTRIGGER zs 2 z t d 5 gt lt LEFT REAR E 2 weet 5 OUTRIGGER rof ores T SEA E 699 6 RIGHT FRONT 2 Qete Y Ji B5j N 2 OUTRIGGER 2 o gt lt LEFT FRONT J2 A8 S OUTRIGGER 7 19 9 ZEN 8 Jis PROPORTIONAL n gt FLOW CONTROL a J1 A12 th DRIVE PARALLEL 42 7 lt 2 20 JI ATI DRIVE PARALLEL e lt 2d gt E 058 Ac E 0 8 l gt lt i 1 J1 A10 DRIVE PARALLEL Lo enl ntum t tuve J1 A8 1 7 12 DRIVE REVERSE ix sx 0 9 2 Nox 2 ut a7 DRIVE FORWARD 4 gt 1 E S J3 A1 E d J1 A6 2 DRIVE REVERSE 5 9 Zi 0 5 a J1 A5 rt DRIVE FORWARD _______ gt EL J9 2 Q _ BRAKE RELEASE E 28 z 2 e z DOWN t 9 PLATFORM UP Su 5 2 SEA PLATFORM 9 ot P J1 A2 Hr X STEER LEFT 9 o uP K 52 STEER R
202. GH IDLE 2 B6 N 1 61 GENERATOR OPTION o N N i gt lt Y GENERATOR ON LED t e 9 288 34 OIL PRESSURE LED GLOW PLUG loz 3 N Q e 23 8 No 5 COOLANT b o TEMPERATURE LED lt Eg ww 2 5 START OIL PRESSURE SWITCH 5 5 O gt J2 A5 o dai Y SCOOLANT jane z 5 9 TEMPERATURE SWITCH 2 J4 B5 o m E 2 FLASHING BEACON OPTION m fs 5 J2 B12 Lj TILT ALARM NS J4 C4 J4 C3 lt PLATFORM DOWN Ir DIT gt 95 3268 ONLY z pues 2 ry gt PLATFORM DOWN 2E SH eis 1 z ru 95 xs m 1718 EH J1 01 C4 05 8 s 8 8 6 ic ir Bees D ne ic H i pe r gy AUTOMOTIVE STYLE HORN 9 9 i 8 9 9 g OPTION ES N HIGH IDLE SOLENOID 00000 6 GLOW PLUG 00000 4 4 8 HOURMETER Ze CT 8 ies m T zc 8118 e 0 oo z O amp FUEL SHUT OFF o H d 8 me mind z 8 t a a T O A z 8 8 l DE ir T 8 5 LA 2 2 9 a si ENGINE STARTER gt gt z E o E J ma 5 5538 5 TRE ip BATTERY 12V
203. GS 3268 RT 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 D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual Genie part number 84240 Kubota DF750 Operator s Manual Genie part number 97359 Kubota DF752 Operator s Manual Genie part number 84250 Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST A PROCEDURES 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 D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual REV C 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 D905 Oper
204. HT DELAY 1 7 e LIMIT SW LIMIT SW p 86 9 xn CR77 5 4 DOWN 85 87 87 DOWN 7 Y10A Em 2 U32 DN rm gt GLOW ans n 1 t fae 70 Me HIGH IDLE Y8 Y7 Y10 SOLENOID 1 t 4 n 1 1 4 4 s w I o r Q M lt lt 55 lt lt AS EM 222 7 938 c a 3 o gt z gt 9 lt d gt 2 m m 0 gt gt aS Q NE 2 o 2 z X 9259 mm 2 2 5 5 9 9 Uu w o Dom gt I 2 2 5 20 e gt m S8 o zE 2 5 lt m c e o mq sz 539 id 20 88 amp 9 5 3 3 87 D E lt m Q 3 lt d 5 3 z m d o 2 z m o 5 Q 8 I gt S o a 9 5 g E 3 z MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7184A Genie A TEREX COMPANY 6 86 GS 2668 GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Electrical Schematic REV CE Models with Diesel Power from serial number GS6803 42382 to GS6805 43594 Part 2 of 3 f CR8 TERMINAL 30 AB2 BATTERY 4 z lt e Hf SWA pee 20A ae
205. IGGER BN15 GENERATOR RF OUTRIGGER BN18 OUTRIGGER ENABLE BN16 STARTING AID BN3 J BK POUT2 E 24 POUT3 Ed POUT4 La 5 POUT6 4 La POUT8 O l V 2 PIN5 8 PIN6 e PIN10 O s PIN19 PIN23 O 22 PIN24 O es T PIN13 O PIN25 O bu PIN25 O 4 me PIN29 O s Wn PIN2 BL ENABLE HIGH BN12 LIFT ENABLE LOW BN13 0 4 O POUT1 RD YE e p DOWN RD BK PIN11 H1 ALARM PLATFORM CONTROLS GASOLINE LPG MODELS WITH OUTRIGGERS PLATFORM amp OUTRIGGER UP DOWN TS21 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 29 Section 6 Schematics July 2007 p Electrical Schematic ANSI Models with Gasoline LPG Power REV A from serial number GS6803 42382 to GS6805 43594 Part 1 of 3
206. IGHT 4 6 59 A TEREX COMPANY G 05 2668 RT 05 3268 RT Part No 52302 Section 6 Schematics July 2007 Electrical Schematic Diesel Models from serial number 38465 to 40173 Part 3 of 3 P2 EMERGENCY STOP C c L BK POWER TO PLATFORM A A RD POWER TO GROUND B B Lwa eroun opos opoz i D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE B B WH GROUND C j C BK POWER TO PLATFORM y T A A RD POWER TO GROUND L REV B P2 EMERGENCY a STOP D D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS VOLTAGE REGULATOR PRINTED CIRCUIT BOARD REGULATOR BN R15 JOYSTICK gt 5K CONTROLLER POTENTIOMETER LPP 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE LERIZRIGHIT PIN18 WHEE 4 PLATFORM CONTROLS MEMBRANE DECAL POUT4 POWER LED L19 POUTS POUT6 29 FAULT LED 125 GENERATOR LED 127 PINS O 6 HIGH TORQUE LED L21 HIGH IDLE LED L23 ENGINE STOP BN1 PIN10 O ENGINE START BN2
207. IL ALTERNATOR GROUND GROUND PLATFORM g ENGINE STARTER KS1 REY SUS s ee 15 20 LL LL oc I H T 2 o Gasoline LPG Models from serial number 41824 to GS6803 Electrical Schematic Part 1 of 3 Section 6 Schematics B1 12v Dc a O T o E lt 4i HB mem voo i 1 I Part No 52302 enie GS 2668 RT GS 3268 RT ATE 6 26 July 2007 Section 6 Schematics Electrical Schematic REV C Gasoline LPG Models from serial number 41824 to GS6803 42381 Part 2 of 3 P1 EMERGENCY STOP QD4 co e l c c T A A t p B D P 2 p meus a G8 OUTRIGGERS DIAGNOSTIC OPTION OPTION DISPLAY BN44 FUNCTION RD WH 1 ENABLE r 14 156 PS3 1 N C PLATFORM PLATFORM 1 s core 1812 1813 LS14 1515 BN90 TS54 BN83 BN84 o LEFT RIGHT LEFT RIGHT La FRONT FRONT RE
208. J4 B5 33000 uf 1 C2 J1 C11 C12 J4 C4 POWER TO CR43 ECM CR25 ENGINE RUN 30 R7 2000 CR15 GLOW CR4 HIGH IDLE J4 C3 J4 B4 J1 C1 C4 30 PLUG 85 86 85 86 85 86 87 85 86 30 J4 B6 J2 B8 o 25 GENERATOR OPTION L27 M 18 GENERATOR ON LED J2 B7 25 OIL PRESSURE LED EN COOLANT CN TEMPERATURE LED J4 B2 4 1 N 4 OIL PRESSURE SWITCH SW2 141 an TEMPERATURE SWITCH SW1 a D 1 J2 B12 l CO m FLASHING BEACON OPTION H1 I TILT ALARM 5 AUXILIARY PLATFORM DOWN GS 3268 ONLY lt PLATFORM DOWN 75 GS 3268 ONLY T J1 A9 8 O AUXILIARY PLATFORM gt DOWN GS 3268 ONLY ru 5 PLATFORM DOWN H2 AUTOMOTIVE STYLE HORN 85 86 OPTION 18 WORK LIGHTS OPTION N 8 HIGH IDLE SOLENOID U32 a 00000 GLOW PLUG 00000 HOURMETER ES7140N Part No 52302 enie GS 2668 RT GS 3268 RT ATE T YH FUEL SHUT OFF d es Qna FUSE
209. LARM PIN11 PLATFORM CONTROLS OUTRIGGERS GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 69 July 2007 REV B bx T tt 1J4 A2 J4 B6 o S GENERATOR OPTION BN68 START N N 1 GENERATOR ON LED ES7140P J2 B8 3 OIL PRESSURE LED 4 COOLANT J2 B7 35 45 TEMPERATURE LED U5 ELECTRONIC CONTROL MODULE 1 e OIL PRESSURE SWITCH EcooLANT J2 A5 ae 0 TEMPERATURE SWITCH gt J4 A5 J4 B5 Ji C11 C12 J2 B12 FLASHING BEACON OPTION I TILT ALARM 5 AUXILIARY PLATFORM DOWN 68 3268 ONLY lt PLATFORM DOWN 95 3268 ONLY J4 C4 33000 uf 1C2 R7 2000 Q J4 C3 J4 C1 C4 J4 B4 4 AUXILIARY PLATFORM gt DOWN GS 3268 ONLY 3 px 4 422 PLATFORM DOWN lt POWER TO ENGINE RUN HIGH IDLE r 1 86 CR43 go 86 CR25 30 CR8 20 FUEL 86 CR15 30 GLOW gt PLUG CR4 cu esl io 1 i AUTOMOTIVE STYLE HORN gs OPTION 8 WORK LIGHTS OPTION 85 87 m 85 87 aN HIGH IDLE SOLENOID o 0000
210. MERGENCY Part No 52302 enie GS 2668 RT GS 3268 RT ATE Diesel Models from serial number 38465 to 40173 Electrical Schematic Part 1 of 3 Section 6 Schematics st D amp Q ks J4 A4 7486 7 i GENERATOR OPTION N HIGH IDLE 2 N e 4 GENERATOR ON LED 5 d 9 2 42 88 ei 9 34 S OIL PRESSURE LED n g 5 COOLANT GLOW PLUG Lo E 42587 N 2 TEMPERATURE LED 26 5 ai lt J4 A2 2 J4 B2l du 4 5 OIL PRESSURE SWITCH START zz 4 E 5 COOLANT 4 gas 74 am TEMPERATURE SWITCH o 8 d J4 A5 n m JEBE 54 gt 0 FLASHING BEACON OPTION J1 C11 C12 sea TILT ALARM 5 4 5 AUXILIARY PLATFORM J4 CA h 72 P 22 DOWN 68 3268 ONLY 3 J4 c3 9 lt PLATFORM DOWN n 5 05 3268 ONLY z c QAAE ox MI 8 AUXILIARY PLATFORM 5 gt DOWN 05 3268 ONLY or uU qM NZ zz 21 9 5 PLATFORM DOWN 62 503 3 8 2 11 4 g 8 s s
211. MPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 5 Fault Codes REV B No power output from ECM to the parallel series valve coil OR ECM does not sense the parallel series valve Coil No power output from ECM to the porportional valve coil OR ECM does not sense the porportional valve coil No power output from ECM to the LPG shut off valve coil OR ECM does not sense the LPG shut off valve coil Machine will not drive Machine will not drive Engine will not start or run on LPG Engine will not start or run OR engine runs then shuts off ECM does not allow machine to function Genie FAULT CODE CHART BEFORE SERIAL NUMBER GS6803 42382 No power output from ECM to parallel series valve coil schematic item W OR bad valve coil No power output from ECM to proportional valve coil schematic item T OR bad valve coil No power output from ECM to LPG shut off coil OR bad coil Low engine oil pressure OR defective oil pressure switch Check wiring and terminal at the parallel series valve coil schematic item W OR replace valve coil Check wiring and terminal at the proportional valve coil schematic item T OR replace valve coil Check wiring at the LPG shut off valve coil OR replace LPG valve coil Check the engine oil level OR check wiring and terminal at the oil pressure switch OR check the wiring and terminal at the ECM OR replace
212. N LED J2 B7 CN OIL PRESSURE LED COOLANT TEMPERATURE LED J4 B2 J4 B1 SW2 141 N 4 OIL PRESSURE SWITCH J1 B1 Swi an TEMPERATURE SWITCH J2 B12 H1 id m FLASHING BEACON OPTION I TILT ALARM 5 AUXILIARY PLATFORM DOWN GS 3268 ONLY lt lt PLATFORM DOWN GS 3268 ONLY AUXILIARY PLATFORM sr gt DOWN GS 3268 ONLY l 1 9 5 PLATFORM DOWN AUTOMOTIVE STYLE HORN 85 86 87 n L30 30 CR5 86 87 OPTION 8 WORK LIGHTS OPTION Q3 i e rue 3 HIGH IDLE SOLENOID ram 00000 4 GLOW PLUG 000901 1 HYDRAULIC OIL COOLER sw4 N O HOURMETER HYDRAULIC OIL OPTION p 7 0 TEMPERATURE SWITCH F9A 20 PLATFORM 4 3 GROUND GROUND KEY SWITCH KS1 EN HYDRAULIC OIL gt 2 COOLING FAN OPTION FUEL SHUT OFF v CB1 20A 2 ENGINE STARTER BATTERY 12V DC oc mE iurc IO z I SE Ls ure zo oQ9o ES7140R G ATE OMPANY
213. N1 E PING ENGINE START BN2 Ed PIN10 O HIGH IDLE E PIN19 4 HORN BN5 T PIN23 O HIGH TORQUE BN6 PIN24 E GENERATOR BN7 JE PIN13 O LPG SELECT BN14 E PIN25 O PLATFORM EXT RET ENABLE BN16 T PIN29 4 STARTING AID RD BL PINs 9 DOWN POUT1 PIN11 O H1 PLATFORM CONTROLS GASOLINE LPG MODELS WITHOUT OUTRIGGERS LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 WH GROUND BK POWER TO PLATFORM RD POWER TO GROUND REV D P2 EMERGENCY a STOP BL DATA LINK HIGH YL LOW enie A TEREX COMPANY PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR 15 JOYSTICK 246 9 5K CONTROLLER MS POTENTIOMETER PP 8 WH BK WH YL 50 5 FUNCTION ENABLE T VBL 5 2 0 bd PLATFORM CONTROLS MEMBRANE DECAL POWER LED L19 LIFT ERROR INDICATOR LED L57 FAULT LED L25 GENERATOR LED L27 HIGH TORQUE LED 121 LPG LED L22 HIGH IDLE LED 123 ENGINE STOP BN1 ENGINE START BN
214. NING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry ME D 5 REV Loosen the set screw on the potentiometer shaft just enough to allow the shaft to rotate With the joystick in the center or neutral position adjust the potentiometer shaft until 2 05V DC is displayed on the voltmeter Tighten the set screw Move the joystick full stroke in both directions several times Return the joystick to the center position Result The voltmeter should read 2 05V DC Result If the voltmeter does not read 2 05V repeat steps 5 through 8 Turn the key switch to the off position Wait a few seconds and then turn the key Switch to platform control Result The error indicator light on the top of the platform control box should not be illuminated and code 30 should not be present on the diagnostic display Result If the error indicator light is illuminated or if code 30 is present on the diagnostic display repeat this procedure beginning with step 5 10 Turn the key switch to the off position 11 Close the lid and install the fasteners Genie GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV 1 3 Function Speed Tuning before serial number GS6803 42382 The raised drive speed and platform lift speeds are determined by the per
215. NSI Models with Gasoline LPG Power from serial number GS6805 43595 to GS6805 44770 Electrical Schematic CE Models with Gasoline LPG Power from serial number GS6803 42382 to GS6805 43594 Electrical Schematic CE Models with Gasoline LPG Power from serial number GS6805 43595 to GS6805 44168 Electrical Schematic CE Models with Gasoline LPG Power from serial number GS6805 44169 to GS6805 44770 Electrical Schematic Diesel Models before serial number 21161 Electrical Schematic Diesel Models from serial number 21161 21837 Electrical Schematic Diesel Models from serial number 21838 to 38464 Electrical Schematic Diesel Models from serial number 38465 40173 Electrical Schematic Diesel Models from serial number 40174 1040939 Electrical Schematic Diesel Models from serial number 40940 1041199 Genio kh Xiv GS 2668 GS 3268 RT Part No 52302 July 2007 Section 6 Rev uU v U O gt gt TABLE OF CONTENTS Schematics continued Electrical Schematic Diesel Models from serial number 41200 to 41823 see 6 70 Electrical Schematic Diesel Models from serial number 41824 to 956803 42381 6 74 E
216. No 52302 GS 2668 RT GS 3268 RT 4 93 Section 4 Repair Procedures July 2007 Platform Overload Components 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 Note Be sure the hydraulic oil level is between the full and add marks on the oil level indicator 1 Models with outriggers Deploy the outriggers and level the machine 2 Apply athin 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 Tagand disconnect the platform controls wire harness from the ECM wire harness Genie GS 2668 RT GS 3268 RT REV B 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
217. OWN AUXILIARY DOWN J2 B9 ENABLE CR15 cl 5 5 STARTING 130 B AID CR4 iwonk ABIA 8 HIGH IDLE LIGHTS m 86 30 B1 T A LS24 1825 AAG rese De i 9 amp LIMIT SW LIMIT SW 5 p 86 30 CR77 5 4 DOWN 85 87 87 L DOWN 7 Y10A g 8932 Fes our lt gt GLOW gt 7004 i 1 ga amp v 4 HIGH IDLE Y8 Y7 Y10 SOLENOID 1 t 4 n 1 1 4 4 s BB G 3 38 2 E gt gt lt gt gt m 4 o o gt gt 55 oe e g D D 2 P z x 9299 o 98 5853 Z 5 E P T 9 29 92 o 85 Em x 2 d 5 m o m 3 9 5 c 55 513 m a 5 J 2 i 9 3 D E lt m X M 5 5 m 5 5 p 9 g 2 2 5 g E 2 z MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7184B Genie A TEREX COMPANY 6 90 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Electrical Schematic REV B CE Models with Diesel Power from serial number GS6805 43
218. PIN3 PIN4 PIN11 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS LIFT ENABLE LOW BN13 PLATFORM UP DOWN TS20 DIESEL MODELS WITH enie A TEREX COMPANY R15 JOYSTICK 26 9 5K CONTROLLER 8 WH BK WH YL sw5 FUNCTION ENABLE T pinis WHBL 2 4 I E e BK PLATFORM CONTROLS uM MEMBRANE DECAL POUT2 E POWER LED 119 POUT3 i LIFT ERROR INDICATOR LED L57 POUT4 A 4 FAULT LED 125 POUTS 2 lt ES 4 GENERATOR LED L27 POUT6 O i HIGH TORQUE LED 121 POUT8 O 4 HIGH IDLE LED L23 L NT PIN5 O ENGINE STOP BN1 PING O e ENGINE START BN2 T PIN10 O 4 AUTO LEVEL BN20 E PIN19 O 4 HIGH TORQUE LF OUTRIGGER BN171 PIN23 22 4 HIGH IDLE BN4 PIN24 O RROUTRIGGER BN24 E OUTRIGGER BN15 PIN25 O OUTRIGGER ENABLE BN16 e PIN25 e GENERATOR RF OUTRIGGER BN18 i Ed PIN29 O gt STARTING AID WH 2 LIFT ENABLE HIGH BN12 JP PIN2 BL ENABLE LOW BN13 PINs o P UP YL PLATFORM amp OUTRIGGER UP DOWN 1621 RD Pouno H1 BK A
219. PROCEDURE enie A TEREX COMPANY GS 2668 GS 3268 RT 4 100 Part No 52302 July 2007 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 Genie Part No 52302 GS 2668 RT GS 3268 RT Section 5 Fault Codes Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement Electrocution hazard Conta
220. Procedures July 2007 Ground Controls 7 1 Auxiliary Platform Lowering Auxiliary Platform Lowering GS 2668 RT before serial number 40207 The manual platform lowering system lowers the platform in the event of a main power failure The manual platform lowering cable is attached to the barrel end of the lift cylinder and is activated next to the ground controls How to Adjust the Manual Platform Lowering Cable 1 Raise the platform approximately 10 feet 3 m 2 Liftthe safety arm move to the center of the scissor arm and rotate to a vertical position 3 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 4 Push the handle on the manual platform lowering cable all the way in 5 Disconnect the cable mounting nut from the lowering valve at the barrel end of the lift cylinder 6 Pull the cable tight and measure the distance between the end of the lowering cable and the end of the lowering valve Result The measurement should be 3 16 to 1 4 inch 4 7 to 6 4 mm 7 To adjust loosen the upper lock nut on the cable mounting bracket Turn the lower lock nut clockwise to decrease the distance or counterclockwise to increase the distance Genio cha REV D 8 Tighten the upper lock nut and repeat step 6 to confirm the distance between the end of the lowering cable and the end of the lowering valve 9 Install the ca
221. QUE 6 VABIO VRBIA ls GENERATOR BN7 ABS ABIS 4 ABS ABE Y36 Y34 Y40 Y44 i n Lo d o E UM k 2 PIN9 s e 7 LF OUTRIGGER ENABLE BN85 1 i O 1 RF OUTRIGGER ENABLE BN86 1 A X 5 44 Dp SEDI Ly PIN11 O LR OUTRIGGER ENABLE BN87 Be MM pute Y35 Y33 Y39 PIN12 6 RR OUTRIGGER ENABLE BN24 i IS situe 522 i f 8 mi o S 8 5 0 04 LIFT FUNCTION BN9 2 2 gt gt Lad 5 m 5 m i ui 9 1 S 5 2 ORGR AUTOLEVEL ENABLE 20 E 2 2 7 d 2 8 8 B B E 4 2 2 q 9 2 PNIS SYSTEM STATUS 150 2 2 2 m 2 m 2 Q i m g n i J1 PIN4 YL E z m 2 3 7 PLATFORM UP DOWN TS20 5 9 a 6 6 S J1 PINS BL X OR 5 o o m d 5 IAS PLATFORM amp OUTRIGGER m m D UP DOWN m 2 2 BD To L 4 J1 PINS BK H1 MACHINE SHOWN IN THE STOWED ee PLATFORM POSITION WITH THE POWER OFF CONTROLS ES7183B enie A TEREX COMPANY 6 44 GS 2668 GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6 45 Section 6 Schematics July 2007 Electrical Schematic CE Models with Gasoline LPG Power REV
222. R FUNCTION ENABLE 7 2 STEER 1 1 BK i X LEFT RIGHT 1 823 ABBA Qoo 2 a gt J2PIN7 AB27 AB26 16 Tasas fABT L J2PIN8 O 1 J2 PIN14 c c c c c c i oC C 7 9 m g g 8 2 2 8 8 POUTI PIN2 HORN BN5 U5 STARTING AID ELECTRONIC S a CONTROL PIN4 ENGINE START BN2 lt o 50 9 97 qm l i a o d PINs oes HIGH TORQUE BN6 ABTS fp PING 0 GENERATOR BN7 ABS AB15 8 d PN gt LPG SELECT BN14 Y36 Y34 Y40 Y44 T d o Vj rne 3 LF OUTRIGGER ENABLE BN85 Poo RF OUTRIGGER ENABLE BN86 A X X 2 M CQ Li BA PIN LR OUTRIGGER ENABLE BN87 Y35 Y33 Y39 RR OUTRIGGER ENABLE BN24 4 4 4 Be 8 x NR ge 5 E LIFT FUNCTION BN9 2 2 gt Db NAE 9 a 5 g S amp PIN14 O 4 ORGR AUTOLEVEL ENABLE BN20 3 3 3 8 B 2 E m 2 gt D 5 m m o o o PIN15 SYSTEM STATUS 150 2 gt m m m m m 2 4 mil 2 2 2 t m D po ud o 5 5 etd et rum im e m 9 J1 PIN4 X 5 m 2 3 2 PLATFORM UP DOWN TS20 E 2 2 gt BL OR o J1PIN3 O o 9 z 8 B N X PLATFORM
223. R OUTRIGGER 7 5 L min E gt I D FUNCTION 2 MANIFOLD 6 5 6 5 24 6 L min 24 6 L min CEN o HS0032D HS0027L Genie 6 104 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Hydraulic Schematic REV B from serial number 40485 to GS6803 42379 Part 2 of 2 PLATFORM SENE IDs OVERLOAD A CYLINDER MANIFOLD OPTION AK L Y7 Y10 aes S 95 3268 1 Q059in gt M X0 Y7A ay O INI E eur dua 2211 e pe bi WU RUE 4 9 DYNAMIC BRAKING Y2 i P M 7 t Oli 1 C MODELS wm 2 1 DYNAMIC BRAKING gt lt Teas LM 89 STEM Som 5 sue Y1B 241 3 bar 0 89 mm Ww x i 5 psi M 4 0 35 Y9 I 1 SERA CENE ESPRIME Zo iue eo F 2800657 193 AFTER SERIAL NUMBER 40958 FUNCTION
224. RE SWITCH 8 d J4 CA 2 e e 8 jac 42 812 zo TILT ALARM I rc 44 4 J1 B1 fn FLASHING BEACON OPTION 2 i z lt PLATFORM DOWN ec i0 a 31 05 3268 ONLY NZ XI C38 cz Lea 25 1 En O amp u og One J1 A9 gt PLATFORM DOWN l 11 Cnc4 P 8 s 8118 S er ah a Gh oa our O r o AUTOMOTIVE STYLE HORN gu 5 1 OPTION o o 9 WORK LIGHTS OPTION a HIGH IDLE SOLENOID G OS d tn CHOKE 4 2 4 8 4 HOURMETER ze LL moe 8 E SE pou eta o E S SPARK PLUG S 5 4 e Tod e 9 N 2 2 gt gt lt DISTRIBUTOR 2118 7 lt a oo o LLI gt lt 5 IGNITION COIL E o r we nl m 5 8 2 T 28 amp ALTERNATOR Sm d zt u 1 2 g EA z gt gt o o gt G eo E 8 4 ENGINE STARTER o x26 2 lt 2 21 28 ms g 53026 ON n 8 sae ms 50 gt oO SO i i ILLI PRES meme Part No 52302 enie GS 2668 RT GS 3268 RT ATE 6 10 July 2007 Section 6 Schemat
225. REGULATOR C j C BK POWER TO PLATFORM A A r RD POWER TO GROUND B WH GROUND D BL DATA LINK HIGH YL DATALINK LOW EMERGENCY REVA P2 STOP PLATFORM CONTROLS PRINTED CIRCUIT BOARD VOLTAGE REGULATOR POUT4 POUTS POUT6 PINS 6 PIN4 PIN11 PIN10 O PIN19 PIN23 PIN24 O PIN25 O PIN29 O PIN1 O PIN2 O R15 JOYSTICK gt 5K CONTROLLER POTENTIOMETER LPP 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE LERIZRIGHIT PIN18 WHEE 4 POWER LED L19 29 FAULT LED 125 GENERATOR LED 127 HIGH TORQUE LED L21 HIGH IDLE LED L23 ENGINE STOP BN1 ENGINE START BN2 HIGH IDLE BN4 HORN BN5 HIGH TORQUE BN6 GENERATOR BN7 STARTING AID BN3 PLATFORM CONTROLS MEMBRANE DECAL PLATFORM EXT RET ENABLE BN16 LIFT ENABLE HIGH BN12 LIFT ENABLE LOW BN13 PLATFORM CONTROLS DIESEL MODELS WITHOUT OUTRIGGERS YL PLATFORM UP DOWN 520 A TEREX COMPANY
226. TION START DOWN G6 OF ey HOUR METER 156 PLAT 86 3 86 86 a 86 4 86 3 86 304 6 DOWN ERI 85 e 85 85 a 85 85 SWITCH 2 99939 5 aus L30 N 5 WORK LIGHTS n E i ujip 224 BN23 BN91 J2 C4 AUXILIARY DOWN J2 B9 ENABLE U19 8 8 4 2 CR15 CR4 STARTING HIGH IDLE AID se 86 30 X A 5 85 87 87 85 87 87A 4700 uF Y7A Tic A T t 0 LEZE ch M J Q7 AX qx CHOKE HIGH IDLE SOLENOID SOLENOID EE a pad Dt Ye y Yio 2 S S 9 5 8 9 5 5 2 93 95 gt o o o gt gt T m T 9 Oe c x o o 0 z 5 z gt lt gt 9 d gt gt DEN e 3 2 T X oS ri z E 2 A 5 gt m m 2 m o 2 o m o 2 0 gt 2 2 20 212 d z o m o 4 52 5 3 z c lt lt o m S 3 i 9 c 6 m m 9 5 bd d o 2 5 o 9 g ES zi o lt G 2 Q i lt lt m 3 o 2 m gt o 8 z m 5 E 5 m 9 g T 9 2
227. TOR ON LED LPG BN14 BN68 SELECT J4 A1 L L42 y 5 OIL PRESSURE LED 4 COOLANT J2 B7 g TEMPERATURE LED J4 B2 N C SW2 141 p N OIL PRESSURE SWITCH ELECTRONIC CONTROL MODULE J4 B1 J2 A5 SW H FB1 J4 A5 E COOLANT TEMPERATURE SWITCH id FLASHING BEACON OPTION J4 B5 1 11 N H1 PLATFORM KS1 CR43 POWER TO ECM CR25 ENGINE RUN J1 C11 C12 J2 B12 I TILT ALARM 5 AUXILIARY PLATFORM CR8 IGNITION J4 C4 CR15 GLOW J4 C3 gt DOWN GS 3268 ONLY lt PLATFORM DOWN ga J4 C1 C4 J4 B4 72 GS 3268 ONLY C AUXILIARY PLATFORM sr gt DOWN GS 3268 ONLY 4 PLATFORM DOWN HIGH IDLE r Ve CR4 W 86 85 2 B1 86 2 mm e rtu N I AUTOMOTIVE STYLE HORN 85 786 85 786 85 LJ 30 87 85 186 4 1 30 7 PLUG 87 LJ 86 30 130 L30 7 OPTION 4 8 WORK LIGHTS OPTION 85 87 Q7 8 HIGH IDLE SOLENOID CHOKE CR1 ENGINE START 86 85 1 HOURMETER
228. Test the Emergency 3 18 B 7 Test the Automotive style Horn 3 19 B 8 Test the Fuel Select Operation Gasoline LPG Models 3 20 B 9 Test the Drive 3 21 B 10 Test the Drive Speed Stowed 3 22 Genio viii GS 2668 RT GS 3268 RT Part No 52302 July 2007 TABLE OF CONTENTS Section 3 Rev X Scheduled Maintenance Procedures continued B 11 Test the Drive Speed Raised Position 3 23 B 12 Inspect the Fuel and Hydraulic Tank Cap Venting Systems 3 24 B 13 Perform Hydraulic Oil Analysis 3 25 B 14 Test the Flashing Beacons if equipped 3 25 B 15 Perform Engine Maintenance Kubota D905 Models 3 25 C Checklist C Procedures C 1 Platform Overload System if equipped 3 26 C 2 Clean the Fuel Tank Diesel 3 27 C 3 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic rette 3 28 C 4 Perform Engine Maintenance Diesel Models 3 29 C 5 Perform Engine Maintenance Kubota D905 and DF750 Models 3 29 C Checklist D Procedures D 1 Check the Scissor Arm Wear
229. 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 AWARNING Crushing hazard The number 4 inner arm index 20 could become unbalanced and fall if not properly supported when removed from the machine 39 Attach a lifting strap from an overhead crane to the lug on the rod end of the upper lift cylinder Raise the rod end of the cylinder to a vertical position Part No 52302 Genie GS 2668 RT GS 3268 RT SCISSOR COMPONENTS 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 AWARNING 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
230. YSTICK 2 LS12 LS13 LS14 LS15 3 4 8 CONTROLLER mo 8 2 J2 PIN13 BN LF RF LR 9 LL 1 J2 PINS LIMT LIMT o lt SWITCH SWITCH SWITCH SWITCH 2 E E UNE GY SW5 swe 0 NO 4 NOt NOS OWENS OR FUNCTION ENABLE lt 2 STEER ZASA BK 4 LEFT RIGHT 1 1 23 18824 L J2 PING zi 2 J2 PIN7 BD AB27 1 26 17 16 7625 L J2 PIN8 1 J2 PIN14 c lt c c c c Ca c toc lt x T T 25 9 9 9 Q 2 25858 i z POUTI PIN2 HORN BN5 U5 PIN3 STARTING AID BN3 ELECTRONIC 5 CONTROL PIN4 ENGINE START BN2 c c c c es x 5 d T 5 9 amp 044246 55 HIGH TORQUE 6 VABIO VRBIA ls GENERATOR BN7 ABS ABIS 4 ABS ABE Y36 Y34 Y40 Y44 i n Lo d o E UM k 2 PIN9 s e 7 LF OUTRIGGER ENABLE BN85 1 i O 1 RF OUTRIGGER ENABLE BN86 1 A X 5 44 Dp SEDI Ly PIN11 O LR OUTRIGGER ENABLE BN87 Be MM pute Y35 Y33 Y39 PIN12 6 RR OUTRIGGER ENABLE BN24 i IS situe 522 i f 8 mi o S 8 5 0 04 LIFT FUNCTION BN9 2 2 gt gt Lad 5 m 5 m i ui 9 1 S 5 2 ORGR AUTOLEVEL ENABLE 20 E 2 2 7 d
231. ace a drain pan or other suitable container under the hydraulic tank Refer to Section 2 Specifications Remove the drain plug from the hydraulic tank and completely drain the tank Bodily injury hazard Spraying AWARNING 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 52302 July 2007 Section Scheduled Maintenance 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 lf equ
232. achine reference point passes over the finish line Refer to Section 2 Specifications 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 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 52302 July 2007 Section 3 Scheduled Maintenance Procedures REV D 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 Startthe 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 Bringthe machine to maximum drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line Part No 52302 Genie GS 2668 RT GS 3268 RT CHECKLIST
233. 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 AWARNING 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 Section 4 Repair Procedures July 2007 SCISSOR COMPONENTS 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 420 from the engine side of the mac
234. arm index 14 16 Support the number 4 inner arm index 13 with a second overhead crane at the non steer end Section 4 Repair Procedures July 2007 SCISSOR COMPONENTS 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 AWARNING 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 AWARNING 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 Genie GS
235. 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 12 Remove the pin retaining fasteners from the slide block pivot pin 13 Place a rod through the pin and twist to remove the pin 14 Remove the slide block and remove the wear pad mounting fasteners 15 Install the new wear pad 16 Repeat steps 12 through 15 for the other wear pad slide block 17 Install the wear pad slide blocks into the drive chassis and install the slide block pivot pins and pin retaining fasteners Section 4 Repair Procedures July 2007 SCISSOR COMPONENTS 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 AWARNING 2odily 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 Two Hydraulic Hose and Fitting Torque
236. art number 84250 Genie GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section Scheduled Maintenance Procedures REV C CHECKLIST D PROCEDURES D 5 D 6 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 D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Perform Engine Maintenance Kubota D905 Models Engine specifications require that this procedure be performed every 1500 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Kubota DF752 Operator s Manual Genie part number 84240 Kubota part number EG601 8916 1 Kubota D905 Operator s Manual Genie part number 84240 Kubota DF750 Operator s Manual Genie part number 97359 Kubota DF752 Operator s Manual Genie part number 84250 Genie Part No 52302 GS 2668 RT GS 3268 RT 3 33 Section Scheduled Maintenance Procedures July 2007 Checklist E Procedures 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
237. as g TUI DRIVE REVERSE 8 G42 He 3 5 B ea DRIVE FORWARD cee ee rs ee ee z TUM J3 A2 N 8 BRAKE RELEASE z 95 S 2 2 5 gt K 5 lt DOWN 9 50 PLATFORM UP Oy p 2 PLATFORM 9 99 ot ga E 1A H 3 X STEER LEFT i o Feit 5 thy 52 STEER RIGHT e 4 6 15 A TEREX COMPANY G 05 2668 RT 05 3268 RT Part No 52302 Section 6 Schematics July 2007 Electrical Schematic Gasoline LPG Models from serial number 21838 to 38464 Part 3 of 3 QD3 BK POWER TO PLATFORM A J A y RD POWER TO GROUND B l WH GROUND 0 D BL DATA LINK HIGH YL DATALINK LOW PLATFORM CONTROLS PRINTED CIRCUIT BOARD P2 EMERGENCY a STOP VOLTAGE REGULATOR BN R15 JOYSTICK gt 5K CONTROLLER 17 POTENTIOMETER 8 WH BK WH YL SW5 SWG STEER FUNCTION ENABLE T RIGHT PIN18 WIUBE 4 BK PLATFORM CONTROLS A WH BRANE DECAL L19 LED 127 HIGH TORQUE LED L21 E p MEM POUT2 4 4 POWER LED POUT3 p2 POUT4 O
238. assembly slightly and return the safety arm to the stowed position Lower the scissor assembly AWARNING 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 AWARNING 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 Part No 52302 July 2007 Section 4 Repair Procedures REV 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 AWARNING 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 AWARNING Crushing hazard The scissor assembly could become unbalanced and fall if no
239. ator s Manual Kubota part number 16622 8916 5 OR the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 Kubota D905 Operator s Manual Genie part number 84240 Genie part number 84240 Kubota DF750 Operator s Manual Kubota DF750 Operator s Manual Genie part number 97359 Genie part number 97359 Kubota DF752 Operator s Manual Kubota DF752 Operator s Manual Genie part number 84250 Genie part number 84250 Genie GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section Scheduled Maintenance Procedures REV C 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 ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach Perform this procedure with the engine off 1 Locate the fuel filter water separator and loosen the vent plug located on the fuel filter water separator head 2 Loosen the drain plug located at t
240. atteries 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 26 7 C Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 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 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 Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST B PROCEDURES 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 ma
241. ay 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 Section Scheduled Maintenance Procedures July 2007 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 ES iss ca El Genie 3 2 GS 2668 RT GS 3268 RT 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 t
242. ble mounting nut onto the lowering valve 10 Raise the platform and rotate the safety arm to the stowed position 11 Pull the manual lowering handle at the ground controls 2 to 3 times to ensure it is functioning correctly CA ob manual lowering cable sheath upper lock nut cable mounting bracket lower lock nut cable mounting nut end of the lowering cable manual lowering valve hydraulic schematic item AE qaroao om 4 42 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV D Auxiliary Platform Lowering GS 3268 RT and GS 2668 RT after serial number 40206 In the event of a main power failure activating the function enable and manual platform lowering buttons at the ground controls will lower the platform There is no adjustment required Before serial number 41824 two 6V DC batteries wired in series supply power for the manual platform lowering function These batteries are located behind the ground control panel After serial number 41823 the auxiliary platform lowering circuit uses the main 12V battery for its power source How to Replace a Manual Platform Lowering Battery before serial number 41824 1 Open the ground controls cover 2 Remove the ground control panel fasteners and open the panel Tag and disconnect the wires from the battery to be removed 4 Remove the battery from the machine Install the new
243. bota D905 Engine Repair procedures and additonal engine information are available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota D905 Workshop Manual Kubota part number 97897 00870 Kubota D905 Operator s Manual Genie part number 84240 Kubota D905 Workshop Manual Genie part number 52229 Genie GS 2668 RT GS 3268 RT REV D 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 Loctitee 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 pump a b pump shaft pump coupler d flex plate e flywheel f 1 32 inch 0 8 mm gap Part No 52302 July 2007 Section 4 Repair Procedures REV D 4 5 Coolant Temperature and Oil Pressure Switches The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 225 107 C If the coolant
244. c display C A4 Highidleinput C4 Power input C4 Diagnostic display D 5 Tachometer signal input C5 Not used C5 Diagnostic display E Not used N Diagnostic display F 2 e 5 a i G B1 Coolant temperature Switch input C8 Ground C8 Diagnostic display H B2 Oil pressure switch input C9 Not used C9 Diagnostic display J B3 Not used C10 used C10 Diagnostic display B4 High idle output C11 Power input C11 Not used B5 Engine start output C12 Power input C12 Not used B6 Generator select output Y29 ali 5230009 OOOO 0 18 pin connector 1 p s 20 000800 1 1200000000008 0060009000000 AMOOOO OOOOO 0 36 LPG select output Gasoline select output Choke glow plug output J4 1 1 J1 Electronic Control Module Ignition fuel output Not used Not used 065520 0 J3 J2 Genie Part No 52302 GS 2668 RT GS 3268 RT COMPANY Section 6 Schematics July 2007 Electronic Control Module Layout from serial number GS6803 42382 to GS6805 44770 To outriggers Flashing beacons
245. c wopuE i r l ins wo ut T 8 c 5 804 E HIGH TORQUE BN6 o o sr00 AB10 AB14 AB7 GENERATOR BN7 ABS AB15 8 d PN gt LPG SELECT BN14 Y36 Y34 Y40 Y44 i do o JD Cj amp ix exl 1 1 LF OUTRIGGER ENABLE BN85 RF OUTRIGGER ENABLE BN86 b PINT OO A X X 2 me L1 LTO int OS LR OUTRIGGER ENABLE BN87 Y35 Y33 Y39 RR OUTRIGGER ENABLE BN24 QUUM d p x x g 8 8 5 LIFT FUNCTION ES gt A a m m o S x PIN14 ORGR AUTOLEVEL ENABLE BN20 i E i 4 5 X 5 o m 2 5 5 m 2 2 Q Q 24 2 2 m 8 9 m o 4 SYSTEM STATUS L50 o z 2 m m m m m 2 X 2 2 2 t Q m E HE LLL MW cuc c 3 x m 9 J1PIN4 2 i i z m E 2 1 PLATFORM UP DOWN TS20 3 z 5 5 9 Ji PINS X E ORE l 5 o O m 8 B PLATFORM 8 OUTRIGGER m m D UP DOWN 0 80 T82 L E J1 PINS o RD H1 MACHINE SHOWN IN THE STOWED ici POSITION WITH THE POWER OFF ES7184B enie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics This page intentionally left blank Genie Part No 52302 GS 2668 RT GS 3268 RT 6
246. centage of total ECM voltage output The speeds of the these functions may be adjusted to compensate for wear in the hydraulic pump and drive motors To adjust the function speeds on machines after serial number GS6803 42382 see 7 2 Function Speed Tuning after serial number GS6803 42381 For further information or assistance consult the Genie Industries Service Department ADANGER 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 ADANGER 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 PLATFORM CONTROLS How to Determine the Revision Level Note Models before serial number 13154 were not adjustable when they were shipped from the factory If the ECM has been updated to revision BO or later or if the machine serial number is after 13153 you can access the revision level of the ECM by using the following procedure 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the oN position at both platform and ground controls 2 Move and hold the function enable toggle switch and the platform up down toggle switch in the down direction Result The revision level of the ECM w
247. chine 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 Genie GS 2668 RT GS 3268 RT REV 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 AWARNING 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 AWARNING inner arm index 24 could become unbalanced and fall if not properly supported when removed fro
248. ct AWARNING with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Spraying AWARNING 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 Section 5 Fault Codes July 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 Identify gt Troubleshoot discovered symptoms A problem still exists 4 Return to 0 0 Perform service problem repair solved Genie 5 2 GS 2668 RT GS 3268 RT 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 Part No 52302 July 2007 Section 5 Fault Codes REV B 01 02 or 03
249. d 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 Genie GS 2668 RT GS 3268 RT REV 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 AWARNING 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 AWARNING 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 AWARNING outer arm index 30 could become unbalanced and fall if not pro
250. d cap to the air cleaner cannister with the retaining clamps 10 Kubota D905 models Swing the engine pivot tray back to its original position and make sure the engine tray locking pin locks into place Genie GS 2668 RT GS 3268 RT REV C 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 403C 11 models B 3 Inspect the Tires Wheels and Lug Nut Torque B 4 Perform Engine Maintenance Perkins 403C 11 Models C4 Perform Engine Maintenance Diesel Models D 2 Replace the Hydraulic Tank Return Filter Part No 52302 July 2007 Section Scheduled Maintenance Procedures REV C CHECKLIST PROCEDURES A 7 A 8 Perform Engine Maintenance Kubota D905 Models Engine specifications require that this one time procedure be performed after the first 50 hours of operation Required maintenance procedures and additional engine information is available in the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 84240 Part No 52302 Genie GS 2668 RT
251. d 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 Push in the red Emergency Stop button to the off position at the ground controls 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 5 July 2007 REV D 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 FO E0 DO and lower Use the yellow platform down arrow to scroll to lift drive cutout Result CUTOUT ON is Showing in the diagnostic display window Result curour orr 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 position GS 2668 GS 3268 RT Use the yellow platform down arrow to sc
252. d plug the high pressure hydraulic hoses from both sections of the hydraulic pump AWARNING 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 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 70 GS 2668 GS 3268 RT Genio cha REVA 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 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 Remove the pressure gauges and connect the hydraulic hoses Part No 52302 July 2007 Section 4 Repair Procedures REVA How to Remove the Hydraulic Pump 1 Tag disconnect and plug the hyd
253. d when removed from the machine Section 4 Repair Procedures July 2007 SCISSOR COMPONENTS 9 99 9 N 60669 6656900909099 GS 3268 Steer End e Non steer End 1 Number 6 pivot pin steer end 16 Number 6 pivot pin non steer end 2 Number 5 center pivot pin 17 Number 5 inner arm 3 Upper lift cylinder rod end pivot pin 18 Number 5 outer arm 4 Number 5 pivot pin steer end 19 Number 5 pivot pin non steer end 5 Number 4 center pivot pins 2 each 20 Number 4 inner arm 6 Number 4 pivot pin steer end 21 Number 4 outer arm 7 Number 3 outer arm 22 Number 4 pivot pin non steer end 8 Number 3 center pivot pin 23 Upper lift cylinder barrel end pivot pin 9 Lower lift cylinder rod end pivot pin 24 Number 3 inner arm 10 Number 3 pivot pin steer end 25 Number 3 pivot pin non steer end 11 Number 2 center pivot pins 2 each 26 Number 2 inner arm 12 Number 2 pivot pin steer end 27 Number 2 outer arm 13 Number 1 center pivot pin 28 Number 2 pivot pin non steer end 14 Number 1 inner arm 29 Lower lift cylinder barrel end pivot pin 15 Number 1 pivot pin s steer end 30 Number 1 outer arm Genie 4 24 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV 3 2 Scissor Assembly GS 3268 RT How to Disassembl
254. 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 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 ourRicGERS orr 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 Genie GS 2668 RT GS 3268 RT REV D CE models with all software revisions 18 Use the yellow platform down arrow to scroll to return to the main menu O 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 52302 July 2007 Section 4 Repair Procedures REV D 7 4 Level Sensor Models without Outrig
255. down arrow to scroll to lift speed Result SPEED is showing in the diagnostic display window Press the lift function enable button 9 REV D FN b I diagnostic display blue platform up button lift function enable button yellow platform down button 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 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 Genie GS 2668 RT GS 3268 RT Section 2 Specifications Part No 52302 July 2007 Section 4 Repair Procedures REV D 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 No
256. e lubricated 225 ft lbs 305 Nm Weight 165 16 7 16 For operational specifications refer to the Operator s Manual 74 8 kg 4 5 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 52302 TEREX COMPANY GS 2668 RT GS 3268 RT 2 1 Section 2 Specifications July 2007 SPECIFICATIONS Performance Specifications Drive speed maximum Platform stowed 3 8 mph 6 1 km h 40 ft 7 2 sec 12 2 7 2 sec Platform raised 0 5 mph 0 8 km h 40 ft 54 6 sec 12 2 54 6 sec Braking distance maximum less than 5 ft less than 1 5 m High range on paved surface Gradeability GS 2668 RT 4096 GS 3268 RT 3596 Function speed maximum from platform controls with maximum rated load in platform GS 2668 RT 28 to 32 seconds 33 to 37 seconds Platform up Platform down GS 3268 RT 38 to 42 seconds 35 to 39 seconds Platform up Platform down Outrigger leveling maximum Front to back 6 6 Side to side 10 6 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice REV D Hydraulic Specifications Hydraulic Oil Specifications Chevron Rykon MV equivalent Multi viscosity Hydraulic oil type Viscosity grade Viscosity index 200 Cleanliness level minimum 15 18 Water content maximum 200
257. e 0 125 gpm 0 47 L min Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice REV D Starter motor Brush length new 0 669 in 17 mm Brush length wear limit 0 453 in 11 5 mm Brush spring tension 50 to 91 ounces 13 7 to 25 5 N Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75AH Cold cranking ampere 900A Reserve capacity at 25A rate 125 minutes Ignition System Ignition spark advance 18 BTDC Ignition coil primary resistance 1 3 to 1 60 75 F 24 Ignition coil secondary resistance 10 7 to 14 5 75 F 24 314 Spark plug wire resistance 2 81 to 4 79kQ 2 Spark plug wire resistance 3 4 to 5 8kQ 3 Spark plug wire resistance 3 57 to 6 09kQ2 Spark plug type BKR4E 11 Spark plug gap 0 039 to 0 043 inches 1 to 1 1 mm Engine coolant Capacity 3 1 quarts 2 9 liters Alternator Output 30A 14V DC Fan belt deflection Genie TEREX COMPANY 1 4 to 3 8 inch 7to9mm 2 8 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 2 Specifications REV D Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok SPECIFICATIONS Seal Lok fittings 1 fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and
258. e 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 10x 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 Genie 4 64 GS 2668 RT GS 3268 RT REV D 28 Raise the platform at least 12 feet 3 6 m O 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 52302 July 2007 Section 4
259. e cables from the upper cable tray support 4 Remove the cables from the number 3 inner arm index 16 and lay the cables off to the side Component damage hazard Cables can be damaged if they are kinked or pinched 5 Remove the mounting fasteners from the upper cable tray supports Part No 52302 Genie GS 2668 RT GS 3268 RT SCISSOR COMPONENTS 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 AWARNING 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
260. e motor and brake assembly may become unbalanced and fall if not properly supported and secured to the lifting jack when removed from the machine GS 2668 RT GS 3268 RT Section 4 Repair Procedures Outrigger Components 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 Two 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 Tagand 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 AWARNING 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 Genie 4 92 GS 2668 RT GS 3268 RT July 2007 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 fa
261. e the Scissor Assembly GS 3268 RT AWARNING 8991 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 Two 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 Part No 52302 Genie GS 2668 RT GS 3268 RT SCISSOR COMPONENTS 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 AWARNING Crushing hazard The number 5 outer arm index 18 could become
262. ed to step 15 Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS 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 OF 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 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 Of OUTRIGGERS ON Section 4 Repair Procedures July 2007 GROUND CONTROLS 15 Use the yellow platform down arrow to scroll to beacons option Result BEACONS is showing in the
263. eference 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 Part No 52302 Genie GS 2668 RT GS 3268 RT 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 Sectiion 2 Specifications Note The brakes must be able to hold the machine on any slope it is able to climb Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST B PROCEDURES 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
264. en 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 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 Section 4 Repair Procedures July 2007 KUBOTA D905 ENGINE 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 How to Repair the Ku
265. enetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Remove the drive motor mounting fasteners Remove the drive motor from the machine Part No 52302 Genie GS 2668 RT GS 3268 RT STEER AXLE COMPONENTS 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 Two Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder AWARNING injury hazard Spraying ydraulic 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 Section 4 Repair Procedures July 2007 STEER AXLE COMPONENTS 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 clev
266. er arm Lift cylinder rod end pivot pin Number 3 pivot pin steer end Number 2 center pivot pins 2 each Number 2 pivot pin steer end Number 1 center pivot pin Number 1 inner arm Number 1 pivot pin s steer end Number 5 pivot pin non steer end 4 18 13 14 15 16 17 18 19 20 21 22 23 Genie GS 2668 RT GS 3268 RT Number 4 inner arm Number 4 outer arm Number 4 pivot pin non steer end Number 3 inner arm Number 3 center pivot pin Number 3 pivot pin non steer end Number 2 inner arm Number 2 outer arm Number 2 pivot pin non steer end Lift cylinder barrel end pivot pin Number 1 outer arm Part No 52302 July 2007 Section 4 Repair Procedures REV C 3 1 Scissor Assembly GS 2668 RT How to Disassemble the Scissor Assembly GS 2668 RT AWARNING 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 Two 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 th
267. erator 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 Genie Part No 52302 GS 2668 GS 3268 RT V Section 1 Safety Rules July 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 my Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Workplace Safety Be sure t
268. erbalance valve outrigger CA Right front outrigger autolevel valve CB Left front outrigger autolevel valve Right rear outrigger autolevel valve CD Left rear outrigger autolevel valve enie July 2007 REV A A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics REVA Filter On Check valve Engine Fixed displacement pump 1 Dual acting cylinder Single acting cylinder Solenoid operated 2 position 2 way valve normally closed Counterbalance valve GCE 9 Solenoid operated 2 position 2 way directional valve Relief valve Lilo LX IK Solenoid operated 3 position 4 way directional valve 0 063 in 1 6 Orifice with size Part No 52302 Genie Hydraulic Symbols Legend Single direction variable speed motor NI Je Priority flow regulator 1 By Solenoid operated 2 position 3 way directional valve E Platform overload pressure switch Hand pump 1 84 Pilot operated check valve with needle valve z Bi directional variable speed motor Solenoid operated 2 position 3 way di
269. ercentage in the diagnostic display window Note this number Press and hold the function enable low speed select button to show the platform lift slow speed percentage in the diagnostic display window PLATFORM CONTROLS 0808806 Stop 3 e sg 0 a steer rocker switch SW6 b function enable low speed select button BN13 horn button d platform extend retract enable BN16 OR outrigger enable button BN16 7 Toincrease or decrease the platform lift speed press and hold the function enable slow speed select button while using the steering rocker switch to adjust the percentage Note The Slow Lift Speed percentage should be set 4 to 6 points less than the Fast Lift Speed percentage 8 Release the function enable slow speed select button 9 Turn the key switch to the off position to save the settings Factory percentage settings Slow lift speed Gasoline LPG models 34 Diesel models 38 Genie Part No 52302 GS 2668 GS 3268 RT 4 9 Section 4 Repair Procedures July 2007 PLATFORM CONTROLS 1 4 Software Configuration before serial number GS6803 42382 The Electronic Control Module ECM contains programming for all configurations of the GS68 RT Models before serial number GS6803 42382 can be adjusted to a different configuration by changing the combination of the DIP
270. f 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 Genie GS 2668 RT GS 3268 RT REV B 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 26
271. front and left rear drive reverse valve coil schematic item A OR bad valve coil Check wiring and terminal at the steer right coil OR check wiring and terminal at ECM Check wiring and terminal at the left right coil OR check wiring and terminal at ECM Check wiring and terminal at the platform up coil OR check wiring and terminal at ECM Check wiring and terminal at the brake coil OR check wiring and terminal at ECM Check wiring and terminals to right front and left rear drive forward valve coil OR check the wiring and terminal at the ECM OR replace the valve coil Check wiring and terminals to right front and left rear drive reverse valve coil OR check the wiring and terminal at the ECM OR replace the valve coil A TEREX COMPANY GS 2668 RT GS 3268 RT Section 5 Fault Codes July 2007 FAULT CODE CHART BEFORE SERIAL NUMBER GS6803 42382 No power output from ECM to the left front and right rear drive forward valve coil OR ECM does not sense the left front and right rear drive forward valve coil No power output from ECM to the left front and right rear drive reverse valve coil OR ECM does not sense the left front and right rear drive reverse valve coil No power output from ECM to the platform down valve coil OR ECM does not sense the platform down valve coil No power output from ECM to the parallel series valve coil OR ECM does not sense the parallel ser
272. g direction of travel 25 30 ft lbs 34 41 Nm 5 Check valve cet Steer CIECUIE eae rice res 25 30 ft lbs 34 41 Nm 6 Check Pons Proportional circuit 25 30 ft lbs 34 41 Nm Relief valve 3500 psi 241 3 bar ues Relief valve for number one section of pump 15 25 ft lbs 20 34 Nm 8 Check Proportional 30 35 in lbs 3 4 Nm 9 Diagnostic nipple Test port 1 d d Testing 10 Diagnostic nipple Test port 2 Jie Testing 11 Relief valve GS 2668 RT 3600 psi 248 2 bar GS 3268 RT 2800 psi 193 bar Kus Platform up auct eerte 15 25 ft lbs 34 41 Nm 12 Check Lise Drive circuit anti cavitation 20 25 ft lbs 27 34 Nm 13 Shuttle Brake 20 25 ft lbs 27 34 Nm This list continues Please turn the page Genie 4 72 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV D MANIFOLDS e Y ss Kel ae La DP eS or 25 amp xe d D 53 5 55 bt P gt m e i T lt gt Y9 9 c d P lt Su Genie Part No 52302 GS 2668 RT GS 32
273. gJ GASOLINE SELECT X FUEL PUMP O LPG SELECT o y GENERATOR OPTION N Q GENERATOR ON LED 5 OIL PRESSURE LED X COOLANT TEMPERATURE LED OIL PRESSURE SWITCH S COOLANT TEMPERATURE SWITCH X TILT ALARM m FLASHING BEACON OPTION lt lt PLATFORM DOWN 95 3268 ONLY PLATFORM DOWN AUTOMOTIVE STYLE HORN I OPTION o WORK LIGHTS OPTION HIGH IDLE SOLENOID O CHOKE HOURMETER SPARK PLUG S A DISTRIBUTOR 2 o 5 IGNITION COIL ALTERNATOR ENGINE STARTER tn BATTERY 12V DC ES0116G t5 ui ii IO zr zi T Ls 20 enie COMPANY GS 2668 GS 3268 RT ATE Part No 52302 6 12 July 2007 Section 6 Schematics Electrical Schematic REV Gasoline LPG Models from serial number 21161 to 21837 Part 2 of 2 P2 EMERGENCY
274. gers Flashing beacon Quick disconnect Toggle switch Voltage regulator a4 gt RII V lt V Potentiometer Resistor GS 2668 RT GS 3268 RT STOP EN P1 EMERGENCY July 2007 CB2 PLATFORM KS1 Gasoline LPG Models before serial number 21161 Electrical Schematic Part 1 of 2 Section 6 Schematics J4 A1 1 y 3j GASOLINE SELECT LPG SELECT ZEE FUEL PUMP 9 yy HIGH IDLE 5 c N Cj LPG SELECT 1954 B 2 14902 JeB6j 4 GENERATOR OPTION CHOKE 52 e 2 TS56 2 g 0 GENERATOR ON LED N lt plusa pgs OIL PRESSURE LED 1552 START S z po 4 9 Ne COOLANT 4 42 45 Ji TEMPERATURE LED at 4 J4 A5 E J4 B2 qd TC OIL PRESSURE SWITCH J4 B5 SAg o J1 011 012 ANM COOLANT B d TEMPERATU
275. gers before serial number 41754 The Electronic Control Module ECM is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor The tilt alarm sounds when the incline of the chassis exceeds 2 to the side 3 to the front or 5 to the rear How to Install and Calibrate the Level Sensor 77177177 hazard Failure to install A DANGER 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 2 Block the wheels at the non steer end of the machine 3 Center a lifting jack under the drive chassis at the steer end of the machine 4 Raise the machine approximately 4 inches 10 cm Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS 5 Placea 1 27 x 10x 10 inch 3 23 x 25 x 25cm thick steel block under both wheels at the steer end of the machine 6 Lowerthe machine onto the blocks 7 Turnthe key switch to platform control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 8 Before serial number 41137 Raise the platform at least 12 feet
276. he 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 Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years Part No 52302 Pre Delivery Preparation 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 respo
277. he bottom of the bowl Allow the water to drain into a suitable container until fuel starts to come out Immediately tighten the drain plug Part No 52302 Genie GS 2668 RT GS 3268 RT CHECKLIST A PROCEDURES a head bolt b ventplug 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 Startthe engine from the ground controls and check the fuel filter water separator for leaks Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST A PROCEDURES 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 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 separato
278. high idle indicator light should turn and the engine should return to low idle Press the engine stop button Result The engine should stop Press the LPG operation button Result The LPG indicator light should be Note Be sure that the LPG tank is full and the valve on the LPG tank is in the oPEN position 7 8 Start the engine and allow it to run at low idle Press the high idle button to allow the engine to run at high idle Result The high idle indicator light should be 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 Genie GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section Scheduled Maintenance Procedures REV D 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 Startthe engine from platform controls 3 Choose a point on the machine i e contact patch of a tire as a visual r
279. hine Crushing hazard The number 2 AWARNING 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 AWARNING 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 AWARNING 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 Genie GS 2668 RT GS 3268 RT REV 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
280. i 3 45 bar of the highest cylinder though at no time less than 360 psi 24 8 bar Low idle 1500 rpm 300 hz High idle 3000 rpm 600 hz Governor all speed mechanical Valve clearance cold 0 0078 in 0 2 mm Engine coolant capacity 3 28 quarts 3 1 liters Engine coolant should be clean soft water with 50 anti freeze concentration ethylene glycol to BS 6580 1992 or ASTMD 3306 89 or AS 2108 1977 Lubrication system Oil pressure hot 2000 rpm 40 to 60 psi 2 76 to 4 14 bar Oil capacity including filter 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 REV D Injection pump make Bosch Injection timing 23 BTDC 3000 rpm Injection pump pressure Fuel requirement 2133 psi 150 bar diesel number 2 D Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75AH Cold cranking ampere 900A Reserve capacity 25A rate 125 minutes Alternator Output 40A 12V DC Fan belt deflection 3 16 inch 5mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie A TEREX COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 REV D Kubota DF750 Engine Displacement 45 21 cu i
281. ic display window Genie GS 2668 RT GS 3268 RT REV D 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 is showing in the diagnostic display window Result ovERLO4D 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 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 EO DO or lower proceed to step 12 Models with software revisions FO and higher proceed to step 15 Part No 52302 July 2007 Section 4 Repair Procedures REV D 12 Use the yellow platform down arrow to scroll to beacons option O 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
282. ics Electrical Schematic REV C Gasoline LPG Models before serial number 21161 Part 2 of 2 P2 EMERGENCY QD 4 STOP BK ES C BK POWER TO PLATFORM A A A A RD POWER TO GROUND B B B B WH GROUND D D 7 D D 4 BL DATA LINK HIGH E E G8 i YL DATA LINK LOW DIAGNOSTIC fe DISPLAY DIP PLATFORM CONTROLS VOLTAGE SWITCH PRINTED CIRCUIT BOARD REGULATOR s piles eps eee oe eee Gia oes ek 7 11 MIT a SS memi FUNCTION RD WH JC1 ENABLE R15 JOYSTICK LS6 LS5 151 5K CONTROLLER PLATFORM PLATFORM EXTENSION 2 F 7 OR POTENTIOMETER DOWN 9 UP DECK 8 WH BK WH YL 71 T E LEVEL o ow SENSOR SW5 SWG RIGHT N C N C 1 CIRCUIT WH BL FUNCTION ENABLE T TS66 PIN18 O m 2 i 1 J id pin15 c E S7 WH gt 5 2 LEVEL L 4 E SENSOR
283. ies valve coil No power output from ECM to the parallel series valve coil OR ECM does not sense the parallel series valve coil Machine will not drive forward Machine will not drive in reverse Platform will not lower Machine will not drive Machine will not drive Genie No power output from ECM to left front and right rear drive forward valve coil schematic item B OR bad valve coil No power output from ECM to left front and right rear drive reverse valve coil schematic item B OR bad valve coil No power output from ECM to platform down coil OR bad valve coil No power output from ECM to parallel series valve coil schematic item X OR bad valve coil No power output from ECM to parallel series valve coil schematic item V OR bad valve coil REV B Check wiring and terminals to left front and right rear drive forward valve coilOR check the wiring and terminal at the ECM OR replace the valve coil Check wiring and terminals to left front and right rear drive reverse valve coil OR check the wiring and terminal at the ECM OR replace the valve coil Check wiring and terminal at the platform down coil OR check wiring and terminal at ECM Check wiring and terminal at the parallel series valve coil schematic item X OR replace valve coil Check wiring and terminal at the parallel series valve coil schematic item V OR replace valve coil A TEREX CO
284. ight rear outrigger 1513 Right front outrigger Y35 Left front outrigger LS14 Left rear outrigger Y36 Right front outrigger LS15 Right rear outrigger Y 39 Outrigger retract M Motor or pump Y40 Outrigger extend M1 Hydraulic oil cooling fan 44 Outrigger extend slow M3 Engine starter n Genio 6 8 GS 2668 95 3268 RT Part No 52302 July 2007 Section 6 Schematics REVA Emergency Stop button A Wire connection No connection circuits crossing 4 Diode 1 CB1 20 Circuit breaker KS1 PLATFORM GROUND GROUND Key switch 7 86 87 85 Control relay EN j ae Button D Pressure switch Temperature switch Capacitor A Limit switch Work lights Solenoid valve with spike supression diode ex Solenoid valve no diode Solenoid valve with redundant coils Electro mechanical solenoid bi men PR ae Alternator 29 Ignition coil Distributor Genie 52302 Electrical Symbols Legend 4 Motor or pump Y t Spark plugs Glow plug s 9 Ec Starter motor 532 533 534 4 535 536 4 537 4 538 4 539 DIP switch Hour meter Level sensor models without outrig
285. il e Eu FUNCTION 1241 3 bar MANIFOLD MN NE ERIS 6 5 6 5 gpm 24 6 24 6 L min 99 6 OF se 9 HYDRAULIC TANK Genie 6 102 GS 2668 RT GS 3268 RT Part No 52302 HS0032C HS0027J July 2007 Section 6 Schematics Hydraulic Schematic REV B from serial number 35557 to 40484 Part 2 of 2 PLATFORM LNO 71 u OVERLOAD A MANIFOLD OPTION AK 5 4 Y7 Y10 MS GS 3268 1 SSS 1 i X Y7A ay O INI E eur dua 4B li 1 1 168 LJ E LA TN a M ya Siei 4 9 DYNAMIC BRAKING ps AA l AC iro gt lt i a Ox I hi Y1B 0 035 241 3 0 89 Ww x 5 psi i 0 35 bar Ke T 4 2800 psi 193 bar FUNCTION 3600 psi 248 2 bar MANIFOLD ee NEST E SENE IE
286. ill appear in the diagnostic display window a diagnostic display window b red Emergency Stop Button P1 c platform up down toggle switch T8566 c function enable toggle switch TS67 Genie Part No 52302 GS 2668 RT GS 3268 RT 4 5 Section 4 Repair Procedures July 2007 PLATFORM CONTROLS How to Adjust the Raised Drive Speed ADANGER Tip over hazard Setting drive speed greater than specifications will cause the machine to tip over resulting in death or serious injury Do not adjust the drive speed higher than specified in this procedure Note The drive function of the GS 2668 RT before serial number 26563 is disabled when the platform is 20 feet 6 1 m or higher while the platform is extended The GS 2668 RT after serial number 26562 is able to drive at full height due to additional counterweight being added to the machine Note The drive function of the GS 3268 RT before serial number 42000 is disabled when the platform is 26 feet 7 9 m or higher while the platform is extended The GS 3268 RT after serial number 41999 is able to drive at full height due to additional counterweight being added to the machine 1 Remove the platform controls from the platform and place the controls near the diagnostic display window at the ground control panel 2 Turn key switch to the off position REV 0 90 9 6 Genie
287. illustration Note Be sure the solenoid fully retracts when activating high idle Genio cha REV B 6 2 Timing Adjustment Complete information to perform this procedure is available in the Perkins 403C 11 Workshop Manual Perkins part number TPD1458 Perkins 403C 11 Workshop Manual Genie part number 84817 solenoid yoke locknut yoke low idle lock nut low idle adjustment screw 4 40 GS 2668 GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures 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 221 105 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 Before serial number GS6803 42382 A fault indicator light at the ground controls should turn on when either switch closes After serial number GS6803 42381 A fault code will be shown in the diagnostic display window at the ground controls whe
288. ing 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 Section 4 Repair Procedures July 2007 SCISSOR COMPONENTS 80 Raise the scissor assembly slightly and return the safety arm to the stowed position Lower the scissor assembly Remove the straps AWARNING 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 AWARNING 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 AWARNING Crushing hazard The scissor assembly coul
289. installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum 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 SAE Dash size Torque 2 4 11 ft lbs 14 9 Nm 3 6 23 ft lbs 31 2 Nm 8 40 ft lbs 54 2 Nm a 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft lbs 188 5 Nm 6 20 172 ft lbs 233 2 Nm 24 208 ft lbs 282 Nm SAE O ring Boss Port tube fitting installed into Steel Lubricate the O ring before installation Be sure that the face seal O ring is seated and retained properly Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight Tighten the nut or fitting to the appropriate torque per given size as shown in the table Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Lok Fittings hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 18 ft lbs 24
290. inted on recycled paper Printed in U S A li GS 2668 RT GS 3268 RT Part No 52302 July 2007 INTRODUCTION Serial Number Legend Genie Model GS 1930 Serial number GS3005A 12345 Model year 2005 Manufacture date 04 12 05 Electrical schematic number 50141 Machine unladen weight 2 714 Ib 1 231 kg Rated work load including occupants 500 Ib 227 kg G S30 05 1 2345 Maximum allowable inclination of the chassis Model Sequence Gradeability N A number Model year Maximum allowable side force 100 Ib 445 N Maximum number of platform occupants 2 Facility code used only for model manufactured Country of manufacture USA in multiple facilities This machine complies with ANSI A92 6 1999 B354 2 01 Genie Industries 18340 NE 76th Street Redmond WA 98052 USA PN 77055 Serial number stamped on chassis Serial label inside cover enie A TEREX COMPANY Part No 52302 GS 2668 GS 3268 RT lii July 2007 This page intentionally left blank Genie iv GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 1 Safety Rules Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Op
291. ion 32 Push in the red Emergency Stop button to the off position at the ground controls GS 2668 GS 3268 33 Turn the key switch to ground control Limit switch legend a maximum height limit switch b down limit switch load sense delay limit switch Genie Part No 52302 GS 2668 RT GS 3268 RT 4 97 Section 4 Repair Procedures July 2007 PLATFORM OVERLOAD COMPONENTS 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 O Result rUNE sPEEDS is showing in the diagnostic display window 1 an diagnostic display blue platform up button lift function enable button 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 O 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 Genie GS 2668 RT GS 3268 RT REV B 39 Pull out the red Emergency Stop butt
292. ipped open the two hydraulic shutoff valves located at the hydraulic tank 23 Operate all machine functions through a full cycle and check for leaks 24 Install the hose cover plate and install the hose cover plate mounting fasteners Part No 52302 Genie GS 2668 RT GS 3268 RT CHECKLIST E PROCEDURES E 2 Perform Engine Maintenance Perkins 403C 11 Models Engine specifications require that this procedure be performed every 2000 hours Required maintenance procedures and additional engine information is available in the Perkins 403C 11 User s Handbook Perkins part number 100816460 Perkins 403C 11 User s Handbook Genie part number 97360 Section Scheduled Maintenance Procedures July 2007 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 REV B E 4 Perform Engine Maintenance Perkins 403C 11 Models Engine specifications require that this procedure be performed every 3000 hours Required maintenance procedures and additional engine information is available in the Perkins 403C 11 User s Handbook Perkins part number 100816460 Perkins 403
293. is pin 2 Remove the tie rod How to Perform the Toe in Adjustment before serial number 33737 1 Straighten the steer wheels 2 Block the tires at the non steer end of the machine 3 Measure the steer tires front to front and back to back using a measuring fixture 4 Center a lifting jack under the steer end of the drive chassis and raise the machine until the steer tires are off of the ground Genie 4 90 GS 2668 RT GS 3268 RT REVA 5 Place blocks under the drive chassis for support 6 Loosen the jam nut on the adjustable end of the tie rod 7 Remove the cotter pin from the clevis pin at the adjustable end of the tie rod Note Always use a new cotter pin when installing a clevis pin 8 Slide the tie rod off of the yoke and adjust it by turning the end Note One half turn on the adjustable end equals approximately 4 inch 6 4 mm change in the front and rear measurements 9 Slide the tie rod onto the yoke Install the clevis pin 10 Lower the machine 11 Repeat step 3 If further adjustment is needed repeat steps 4 through 9 12 Install a new cotter pin in the tie rod clevis pin 13 Tighten the jam nut against the adjustable end of the tie rod Part No 52302 July 2007 Section 4 Repair Procedures REVA 12 1 Non steer Axle Components Drive Motor and Brake How to Remove a Drive Motor and Brake Component damage hazard Repairs to the motor should only be
294. 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 Two Hydraulic Hose and Fitting Torque Specifications 1 Start the engine and raise the platform approximately 10 feet 3 m 2 Liftthe 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 AWARNING C shing hazard Keep hands clear of the safety arm when lowering the platform 4 Tagand 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 AWARNING end injury hazard Spraying ydraulic 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 Section 4 Repair Procedures July 2007 SCISSOR COMPONENTS REV 8 Lower the cylinder to a horizontal position If removing the upper lift cylinder disregard step 9 Note alpha callouts refer to corresponding notes on 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 UPPER CYLINDER
295. isher 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 When checking for positive tank cap venting air should pass freely through the cap Genie GS 2668 RT GS 3268 RT REV D 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 Remove the breather cap from the hydraulic tank 6 Checkfor proper venting O 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 Part No 52302 July 2007 Section Scheduled Maintenance Procedures REV D CHECKLIST B PROCEDURES B 13 B 14 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
296. isplacement 0 488 cu in per revolution pump 1 8 cc Flow rate 3600 rpm 6 5 gpm pump 1 24 6 L min Displacement 0 488 cu in per revolution pump 2 8 cc Flow rate 3600 rpm 6 5 gpm pump 2 24 6 L min Hydraulic tank return filter Function manifold 10 micron with 25 psi 1 7 bar bypass System relief valve pressure pump 1 3500 psi System relief valve pressure pump 2 Lift relief valve pressure GS 2668 RT Lift relief valve pressure GS 3268 RT Steer relief valve pressure Steer flow regulator Outrigger manifold Relief valve pressure Generator manifold Relief valve pressure Flow rate Drive motors Displacement Part No 52302 SPECIFICATIONS Manifold Component Specifications Plug torque SAE No 2 50 in lbs 6 Nm SAE No 4 13 ft lbs 18 Nm SAE No 6 18 ft lbs 24 Nm SAE No 8 50 ft lbs 68 Nm SAE No 10 55 ft lbs 75 Nm SAE No 12 75 ft lbs 102 Nm Valve Coil Resistance 241 3 bar Description Specification 3500 psi DOS valve 3 position 4 way 4Q 241 8 bar 12V DC with diode schematic items A and B 3500 psi Solenoid valve 2 position 4 way 7 50 24471 ar 12V DC with diode schematic item P 2 Solenoid valve 3 position 4 way 7 50 2 E 12V DC with diode schematic item R Proportional valve 50 1500 psi 12 DC schematic item T 103 4 bar Solenoid valve 2 position
297. iving lights 53 lt Fuel selec CR43 Power to ECM T554 Engine high idle D Power supply 55 Function enable TS56 Glow plug D1 Alternator D2 Generator option 2 E 07 Voltage regulator 12V DC to 5V DC FURCHon enape Platform control box enclosure U Electronic component FB1 Flashing beacons option U3 P rimed Circul m F9 30A fuse 5 ectronic contro module U19 Ignition coil 8 Gauge i U20 Spark plug s 026 Distributor Diagnostic display d U32 lt Glow plug GND Ground Y Valve coi H Horm or alarm Y1 Drive parallel H1 Alarm level sensor Y1A Drive parallel H2 Automotive style horn Y1B Drive parallel jc4 J oystick controller drive steer platform up down Y2 Brake release 51 Key switch Steer right L LED or light 4 Steer left L18 Emergency stop Y5 Drive reverse L19 Power Y5A Drive reverse 121 High torque selected Y6 Drive forward 123 High idle selected Y6A Drive forward L25 Fault Y7 Platform down L27 Generator selected Platform down 65 3268 only L29 Driving lights Y8 lt Platform up L41 Coo ant temperature Y9 Proportional flow control L42 0il pressure Y10 Auxiliary platform down GS 3268 only LS Limit switch before serial number 40207 151 Extension deck Y10A Auxiliary platform down 65 3268 only LS5 Platform up Y29 Generator on option 156 Platform down Y33 Left rear outrigger LS12 Left front outrigger Y 34 R
298. k Genie part number 97360 Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST B PROCEDURES 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 orr position Result The engine should stop and no functions should operate Genie GS 2668 RT GS 3268 RT REV D 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
299. lant capacity 3 3 quarts 3 1 liters Lubrication system Oil pressure 36 to 64 psi 2 48 to 4 41 bar Oil capacity including filter 5 4 quarts 5 1 liters Cil 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 SPECIFICATIONS Injection system Injection pump make Bosch MD Injection timing 18 to 21 BTDC Injection pump pressure 1991 psi 137 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75 Cold cranking ampere 900A Reserve capacity 25A rate 125 minutes Alternator Output 30A 14V DC 1 4 to 3 e inch 7 to 9 mm Fan belt deflection Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 52302 TEREX COMPANY GS 2668 RT GS 3268 RT Section 2 Specifications July 2007 SPECIFICATIONS Perkins 403C 11 Engine Displacement 68 9 cu in 1 13 liters Number of cylinders 3 Bore and stroke 3 03 x 3 19 inches 77 x 81 mm Horsepower gross intermittent 26 1 3000 rpm 19 5 kW Firing order 1 2 3 Compression ratio 23 1 Compression pressure 425 psi 29 3 bar Pressure of the lowest cylinder must be within 50 ps
300. latform ECM communication Troubleshoot control cable OR PLATFORM ECU error System shutdown troubleshoot platform controls FAULT 20 Engine start button fault at CHASSIS START Red ground controls Engine will not start Replace ECM SW FAULT 21 Starting aid button fault at TN CHASSIS CHOKE Red ground controls Starting aid disabled Replace ECM SW FAULT 22 Up switch fault at ground T CHASSIS UP SW Red controls Platform up function inoperable Replace ECM FAULT 23 Platform up down enable Platform up down functions CHASSIS LIFT SW Ped button fault at ground controls disabled Replace ECM FAULT 24 Red Down fault at ground Platform down function disabled Replace ECM DOWN SW FAULT controls 25 Red Left turn switch fault Malfunctioning Steer left Troubleshoot steer left microswitch LEFT TURN SW g ut microswitch FAULT 26 Red Right turn switch fault Maltunctioning steer right Troubleshoot steer right microswitch RIGHT TURN SW ght tu ult microswitch 9 FAULT 27 Function enable switch on Release function enable switch on DRIVE ENABLE Red joystick is activated when Machine functions disabled joystick before power up OR replace SW FLT machine is turned on joystick 28 Drive joystick off neutral when Release joystick before power up OR OFF NEUTRAL Red machine is turned on Machine functions disabled replace joystick DRIVE JOYSTICK 29 Lift enable button fault at the Troubleshoot button OR replace printed
301. ld result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton 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 Part No 52302 Genie GS 2668 RT GS 3268 RT 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 O 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 specific gravity of 1 217 or below Proceed to step 7 7 Perform an equalizing charge OR fully charge the b
302. lectrical Schematic Diesel Models from serial number 21838 to 38464 Part 2 of 3 QD4 c A A Ay B B D D A E E ioc E USEDON GS 3268ONLY i 1 G8 AFTERSERIAL OUTRIGGERS DIAGNOSTIC NUMBER 26562 OPTION OPTION DISPLAY TS67 FUNCTION RD WH ENABLE m Lon HE i I 1 m LS6 LS5 181 PS3 PLATFORM PLATFORM EXTENSION PLATFORM 1 1 O Eo 1612 1513 LS14 LS15 i Aj _ D LEFT RIGHT LEFT RIGHT o _ 1 1 1 1 FRONT FRONT REAR REAR 1 1 4 1 1 OUTRIGGER OUTRIGGER OUTRIGGER OUTRIGGER 1 1 NC NC i m 7175664 c RH ee E B lu lu lu lo B c N O 5 gt 2 J3 MODELS a 5 gt WITHOUT LEVEL 5 l 5 OUTRIGGERS SENSOR 2 alee BN Ac i z ce ee es eee e s 5 5 s B 5 5 5 ae eisoss 9 l U5 5 295 2 3 ELECTRONIC CONTROL MODULE 4 4 E WESS
303. lectrical Schematic ANSI Models with Diesel Power from serial number GS6803 42382 to GS6805 43594 6 78 Electrical Schematic ANSI Models with Diesel Power from serial number GS6805 43595 to GS6805 44770 6 82 Electrical Schematic CE Models with Diesel Power from serial number GS6803 42382 to GS6805 43594 6 86 Electrical Schematic CE Models with Diesel Power from serial number GS6805 43595 to GS6805 44168 6 90 Electrical Schematic CE Models with Diesel Power from serial number GS6805 44169 to GS6805 44770 6 94 Hydraulic Schematics Component Call out Legend 6 98 Hydraulic Symbols Legend sse 6 99 Hydraulic Schematic before serial number 35557 6 100 Hydraulic Schematic from serial number 35557 to 40484 6 102 Hydraulic Schematic from serial number 40485 to GS6804 42379 6 104 Hydraulic Schematic Part No 52302 from serial number GS6805 42380 to GS6804 43183 6 106 Hydraulic Schematic from serial number GS6804 43184 to GS6805 44770 6 108 Genie GS 2668 RT GS 3268 RT XV July 2007 This page intentionally left blank Genie GS 2668 RT GS 3268 RT Part No 5230
304. ls 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 A 9 Engine maintenance Kubota models Perform every 200 hours B 14 Flashing beacons if equipped Perform every 400 hours A 10 Engine maintenance Kubota models B 15 Engine maintenance Kubota D905 models A 11 Drain filter separator Diesel models Perform every 1 2 months A 12 Engine maintenance Kubota D905 models Comments Genie Part No 52302 COMPANY GS 2668 RT GS 3268 RT Section Scheduled Maintenance Procedures July 2007 MAINTENANCE INSPECTION REPORT Model Checklist C Rev C Checklist E Rev B C 1 Platform overload Serial number if equipped E 1 Testor replace hydraulic oil Dale C 2 Fuel tank Date Diesel models E 2 Engine maintenance Perkins 403C models Hour meter C 3 Breather cap models with optional oil Machine owner C 4 Engine maintenance Diesel models Inspected by print Perform every 800 hours E 3 Engine maintenance Gasoline LPG models Perform every 3000 hours E 4 Engine maintenance Perkins 403C models C 5 Engine maintenance Kubota D905 DF750 Inspector title Checklist D
305. ly 2007 Electrical Schematic ANSI Models with Diesel Power from serial number GS6803 42382 to GS6805 43594 Part 1 of 3 REVA KS1 1 EMERGENCY STOP 21 p of S T PLATFORM CONTROL 05 44 HERE 1 oe GROUND 1 4 t ABUS 2 CB2 20A 7 ABS ABS CR41 1 CR23 N C CONTROL CR42 CR5 CR8 ENGINE AUXILIARY 1 HORN IGNITION START DOWN G6 OF a HOUR METER 156 PLAT 86 30 O 86 30 2 86 30 5 86 30 4 86 30 8 86 30 6 DOWN ERI 85 s 85 a 85 SWITCH US 5 EM 200 5 BAT 8 A I d Enters D ad BN23 BN91 J2 C4 e AUXILIARYDOWN AUXILIARY DOWN J2 B9 gt gt a 130 9 30 CR15
306. m 4 Liftthe safety arm move to the center of the scissor arm and rotate to a vertical position 5 Lower the platform onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the platform 6 Locate the level sensor enclosure on the chassis under the limit switches at the steer end of the machine Remove the enclosure cover retaining fasteners and the cover Level sensor after serial number 41199 level sensor max height limit switch CE models down limit switch load sense delay limit switch CE models Section 4 Repair Procedures July 2007 GROUND CONTROLS Install the level sensor 7 Tagand disconnect the wire harness from the level sensor 8 Remove the fasteners securing the level sensor to the chassis Remove the level sensor from the machine 9 Install the new level sensor onto the machine with the X on the level sensor base closest to the steer end of the machine Install and tighten the level sensor retaining fasteners ADANGER 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 10 Connect the wire harness to the level sensor 11 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the
307. m 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 45 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 Genie GS 2668 RT GS 3268 RT REV 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 AWARNING 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 cra
308. m controls OUTRIG SW FLT controls 36 Right rear outrigger enable Troubleshoot button OR replace printed RIGHT REAR Red button fault at platform Outriggers disabled circuit board at platform controls OUTRIG SW FLT 37 Outrigger autolevel enable Troubleshoot button OR replace printed AUTO LEVEL Red button fault at platform Outriggers disabled circuit board at platform controls SWITCH FAULT controls 49 High torque drive function will not ie DRIVE COIL 1 Red Drive coil 1 Y1 fault operate Troubleshoot coil OR wiring FAULT 50 7 A High torque drive function will not m DRIVE COIL 2 Red Drive coil 2 Y1A fault operate Troubleshoot coil OR wiring FAULT 51 High torque drive function will not ie DRIVE COIL 3 Red Drive coil 3 Y1B fault operate Troubleshoot coil OR wiring FAULT 52 Red Proportional coil Y9 fault Lift and outrigger functions are Troubleshoot coil OR wirin FUNC PROP COIL disabled 9 FAULT 54 Red Up coil Y8 fault Platform will not raise Troubleshoot coil OR wiring UP COIL FAULT DOWN COIL Red Down coil Y7 fault Platform will not lower Troubleshoot coil OR wiring FAULT RIGHT TURN COIL Red Right turn coil Y3 fault Machine will not turn right Troubleshoot coil OR wiring FAULT LEFT TURN COIL Red Left turn coil Y4 fault Machine will not turn left Troubleshoot coil OR wiring FAULT BRAKE COIL Red Brake release coil Y2 fault Brakes will not release Troubleshoot coil
309. m the machine 61 Attach a lifting strap from an overhead crane to the number 2 outer arm index 427 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 Part No 52302 July 2007 Section 4 Repair Procedures REV 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 AWARNING 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
310. 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 52302 Genie GS 2668 RT GS 3268 RT 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 O Result The beacons should flash 2 Turn the key switch to platform controls Result The beacons should flash B 15 Perform Engine Maintenance Kubota D905 Models Engine specifications require that this procedure be performed every 400 hours Required maintenance procedures and additional engine information is available in the Kubota D905 Operat
311. mponents 11 1 Yoke and Drive Motor iei en e eH ee 4 88 1152 Steer ERE 4 89 11 3 TG 4 90 Non steer Axle Components 12 1 Drive Motor and 4 91 A Outrigger Components 13 1 Outrigger Cylinder 4 92 B Brake Release Hand Pump Components 14 1 Brake Release Hand Pump 4 93 B Platform Overload Components 15 1 Platform Overload System sss 4 94 Genie xij GS 2668 GS 3268 RT Part No 52302 July 2007 MI TABLE OF CONTENTS Section 5 Rev Fault Codes EE TREE 5 1 Fault Code Chart before serial number 156803 42382 5 3 Fault Code Chart from serial number GS6803 42382 to GS6805 44770 5 9 Section 6 Rev Schematics CL 6 1 Electronic Control Module Layout before serial number GS6803 42382 6 2 A Electronic Control Module Pin Out Legend before serial number 456803 42382 6 3 A Electronic Control Module Layout from serial number GS6803 42382 to 56805 44770 6 4 A Electronic Control Module Pin Out Legend from serial number GS6803 42382 to 56805 44770
312. n 0 74 liters Number of cylinders 3 Bore amp stroke 2 68 x 2 68 inches Section 2 Specifications We Starter motor SPECIFICATIONS Brush length new 0 669 in 17mm Brush length wear limit 0 453 in 11 5 mm Brush spring tension 50 to 91 ounces 13 7 t0 25 5 Horsepower Gross intermittent 23 8 3600 rpm 17 7 3600 Battery Firing order 1 2 3 12V DG Low idle 1500rpm COVP SER 300127 Quantity 1 High idle 3300 rpm Ampere hour 75 660 hz Cold cranking 900A Governor centrifugal ball mechanical Reserve capacity at 25A rate 125 minutes Compression ratio 9 1 Ignition System Compression pressure 128 to 185 psi 8 8 to 12 7 bar Ignition spark advance 18 BTDC Valve clearances cold 0 0057 to 0 0072 inches Ignition coil primary resistance 1 8 to 1 60 0 145 to 0 085 mm 75 F 24 Lubrication system Ignition coil secondary resistance 10 7 to 14 5 kQ 75 F 24 Oil pressure 28 to 64 psi operating temperature 3850 rpm 1 9 to 4 4 bar Spark plug wire resistance 10 to 22kQ Oil capacity including filter 3 9 quarts Spark plug type BCP4ES 11 3 7 liters Spark plug gap 0 039 to 0 043 inches Oil viscosity requirements 1 0 to 1 1 mm Units ship with 15W 40 Engine coolant Extreme operating temperatures may require the use of alternative engine oil
313. n either switch closes How to Repair the Perkins 403C 11 Engine Repair procedures and additonal engine information are available in the Perkins 403C 11 User s Handbook Perkins part number 100816460 OR the Perkins 403C 11 Workshop Manual Perkins part number TPD1458 Perkins 403C 11 Operator s Manual PERKINS 403C 11 ENGINE 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 ACAUTION 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 Ibs 10 Nm Note Always use pipe thread sealant when installing a new switch Genie part number 97360 Perkins 403C 11 Workshop Manual Genie part number 84817 Genie Part No 52302 GS 2668 RT GS 3268 RT Section 4 Repair
314. nd then torqued to specification during installation Refer to Section Two 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 Genie GS 2668 RT GS 3268 RT REV D 4 Turn the key switch to platform control and pull out the red Emergency Stop buttons to the position at both the ground and platform controls 5 Startthe engine and raise the platform approximately 10 feet 3 m 6 Liftthe 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 AWARNING 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
315. ne 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 AWARNING outer arm index 21 at the ground controls side could become unbalanced and fall if not properly supported when removed from the machine Part No 52302 July 2007 Section 4 Repair Procedures REV C 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 AWARNING Crushing hazard
316. nect the wiring from the fuel shutoff solenoid 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 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 Start the engine from the ground controls and check for hydraulic leaks Part No 52302 GS 2668 RT GS 3268 RT 4 71 Section 4 Repair Procedures July 2007 Manifolds REVD 9 1 Function Manifold Components The function manifold is located inside the hydraulic tray Index Schematic No Description Item Function Torque 1 valve 3 position 4 way Controls flow to the steer end ground controls side drive motor and the non steer end engine side drive motor in forward and reverse 30 35 in lbs 3 4 Nm 2 valve 3 position 4 way Basis Controls flow to the steer end engine side drive motor and the non steer end ground controls side drive motor in forward and reverse 30 35 in lbs 3 4 Nm 3 Check Drive speed select circuit 25 30 ft lbs 34 41 Nm Check Prevents engine from running backwards when on an incline and reversin
317. nie Industries Service Department Check for stuck toggle switch OR test or replace the toggle switch Check for stuck toggle switch OR test or replace the toggle switch Check for stuck toggle switch OR test or replace the toggle switch Check or replace platform control panel switch board or replace the platform controls main circuit board Check or replace platform control panel switch board or replace the platform controls main circuit board Check for stuck steer microswitch OR test or replace the steer microswitch Part No 52302 COMPANY GS 2668 RT GS 3268 RT Section 5 Fault Codes July 2007 FAULT CODE CHART BEFORE SERIAL NUMBER GS6803 42382 ECM does not allow machine to function ECM does not allow machine to function ECM does not allow machine to function ECM does not allow machine to function ECM does not allow machine to function ECM does not allow machine to function Engine will not start Machine will not operate from platform Engine will not start Machine will not operate from platform Engine will not start Machine will not operate from platform Engine will not start Machine will not operate from platform Engine will not start Machine will not operate from platform Engine will not start Machine will not operate from platform Platform controls steer right rocker switch faul
318. nsibilities manual enie A TEREX COMPANY Genie UK The Maltings Wharf Road Grantham Lincolnshire Redmond WA 98073 9730 NG31 6BH England 425 881 1800 44 1476 584333 Copyright 2002 by Genie Industries Genie is a registered trademark of Genie Industries Rev B Genie Industries USA 18340 NE 76th Street PO Box 97030 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 no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section Scheduled Maintenance Procedures July 2007 EEIN This page intentionally left blank Genie 3 4 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section Scheduled Maintenance Procedures Maintenance Inspection Report Model Serial number Date
319. o 52302 July 2007 Section 4 Repair Procedures REV C 1 1 Circuit Boards How to Remove the Platform Controls Circuit Board 1 Pushin 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 AWARNING 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 Part No 52302 Genie GS 2668 RT GS 3268 RT 4 3 PLATFORM CONTROLS 1 2 Joystick Controller Maintaining the joystick at the proper setting is essential to safe machine operation The joystick should operate smoothly over its entire range
320. o 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 are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure that all tools and working areas 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 Indicates a potentially hazardous oy A CAUTION situation which if not avoided 2 other fluids Use an approved container may cause minor or moderate Please be environmentally safe injury Be sure that your workshop or work area Indicates a potentially hazardous is properly ventilated and well lit situation which if not avoided ZU may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3l such as moving parts free swinging or unsecured components when lifting or placing loads
321. o 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 Part No 52302 Genie GS 2668 RT GS 3268 RT CHECKLIST C PROCEDURES 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 well ventilated 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
322. of 3 CR8 TERMINAL 30 2 BATTERY tswa F9AC 717 NO oe 20A f CR17 recs 8 85 CIRCUIT BOARD HYDRAULIC t OIL COOLER 1 OPTION LEVEL m 57 SENSOR MODELS WITHOUT BATTERY QUTRIGGERS 2 AB29 rs c U5 S ELECTRONIC CONTROL MODULE S 5 c c c c c c B gt i gt E T S 808 S S 2 6 gt 5 B l B d 9 AB22 ABTS Y4 Y1 Y1A Y2 Y6 Y6A Q1 Q2 1 t Ex 8 x T A EX P EX o8 swi H5 FB1 1 Y5 Y5A Y9 Y29 n 4 i 4 4 n 4 4 4 n L 4 4 2 9 lt Ss 8 8 3 amp N gt 2 w m gt gt mv 9 o 4 4 3 o 2 3 3 rn v o 9 m 8 z 5 m m 2 gt 2 5 2900 9 m 93 2 7 m m z A m m z lt 5 gf 2 i 2 y m m 2 m m 3 5 2 5 gt m 9 3 2 m A BB a gt 2 m z lt 2 AO 9 7 E
323. on 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 Part No 52302 July 2007 Section 4 Repair Procedures REV B 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 po
324. onent damage Dealer Service is required Start the engine from the ground controls and raise the platform 9 to 10 feet 2 7 to 3 m Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position Lower the platform onto the safety arm Turn the machine off AWARNING Crushing hazard Keep hands 4 5 clear of the safety arm when lowering the platform 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 GS 2668 RT before serial number 26563 and GS 3268 RT before serial number 41200 Remove the platform extension limit switch mounting fasteners and remove the limit switch Do not disconnect the wiring Genie GS 2668 RT GS 3268 RT Part No 52302 REVA 6 Raise the platform and return the safety arm to the stowed position 7 Lowerthe platform to the stowed position and turn the machine off 8 Remove the mounting fasteners that secure the platform controls quick disconnect plug to the platform 9 Twist the connector to disconnect the platform controls from the plug 10 Remove the platform control box from the platform and lay it off to the side Component damage hazard The platform controls wiring can be damaged if it is kinked or pinched 11 Remove the cover to the AC power to platform outlet Tag and disconnect the wiring from the
325. onfiguration of Emergency Stop button to the on position at the DIP switch settings both the ground and platform controls and turn the key switch to ground control Do not start f the engine 7 Toconfirm the settings pull out the red 8 Move and hold the platform up down toggle D switch in the up direction and activate the function enable toggle switch from the ground controls Result The diagnostic display window located on the ground control panel will display a configuration number without the dot b illuminated This configuration number indicates the current configuration of the machine Note Configuration code that is less than 100 will be shown as a constant display Configuration code that is greater than 99 will be shown as a flashing display a red Emergency Stop button P2 b switch SW25 c control box d enlarged view of DIP switch SW25 e circuit board U3 f diagnostic display window a 4 Locate the DIP switch on the printed circuit b red Emergency Stop Button P1 DIP switch settings to c platform up down toggle switch TS66 board Move the 2 9 function enable toggle switch TS67 correspond with the configuration of the machine options indicated in the chart See 1 4 Software Configuration 5 Apply dielectric
326. ons and or toggle switches and LEDs All of these components are replaceable though only the potentiometer equipped joystick used before serial number GS6803 42382 is serviceable On models before serial number GS6803 42382 the platform controls are also used to tune the performance of the machine The function speed parameters in the Electronic Control Module are easily adjusted by moving the joystick pressing a button or activating a toggle switch in a specific order when the ECM is in the programming mode PS showing in the diagnostic display window For further information or assistance consult the Genie Industries Service Department 9060 f ar QOO D i c wf 9 Cimi See PI e Platform controls after serial number GS6803 42381 alarm H1 function enable high speed select button for platform up down function BN12 c function enable low speed select button for platform up down function BN13 d platform up down toggle switch T5820 OR platform up down and outrigger up down toggle switch TS21 om e circuit board U3 f DIP switch SW25 9 joystick controller JC1 h potentiometer i red Emergency Stop button P2 Genie 4 2 GS 2668 RT GS 3268 RT Part N
327. or s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 84240 Section 3 Scheduled Maintenance Procedures July 2007 Checklist C Procedures 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 Tagand 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 Tagand disconnect the black wire of the maximum height limit switch wire harness from the A10 terminal of the terminal strip Genie GS 2668 RT GS 3268 RT REV 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
328. ot used A4 Data link high A5 Drive forward Y6 5 Key switch power A5 Data link low Drive reverse Y5 Level sensor input rear outrigger input A7 Drive forward Y6A 7 Platform overload input A8 Drive reverse Y5A front outrigger input B1 Left rear outrigger output AQ Platform down Y7 A9 Not used B2 Right rear outrigger output Y34 A10 Drive parallel Y1 A10 Right front outrigger input B3 Not used A11 Drive parallel Y1A A11 Not used B4 Ground from platform A12 Drive parallel Y1B A12 Not used B5 Right rear outrigger input B6 Driving lights output B1 Flashing beacon FB1 B1 Auto level sensor B2 Left front outrigger output Y35 B2 Not used C1 Not used Proportional flow control Y9 B3 Auto level sensor C2 used B4 Not used B4 Not used used B5 Right front outrigger output Y36 B5 Not used C4 Not used B6 Outrigger extend Y40 B6 Not used C5 used B7 Outrigger retract Y39 B7 Coolant temperature LED C6 Not used B8 Outrigger extend slow Y44 B8 Oil pressure LED B9 Not used B9 Not used B10 Not used B10 Level sensor output J4 Connector B11 Not used B11 Horn relay output 18 pin B12 Not used B12 Alarm output LPG select input in di _ A2 start input E die Diagnostic display A Choke glow plug input put C2 Diagnostic display B dine Jin C3 Power input C3 Diagnosti
329. ote Be sure there are threads showing through the top of the adjusting fasteners O Result The tilt sensor alarm should not sound 20 After serial number 41199 Raise the platform and rotate the safety arm to the stowed position 21 Lower the platform to the stowed position 22 Raise the machine slightly 23 Remove the blocks from under both wheels 24 Lower the machine and remove the jack 25 Remove the blocks from the wheels at the non steer end of the machine 26 Block the wheels at the steer end of the machine 27 Center a lifting jack under the drive chassis at the non steer end of the machine 28 Raise the machine approximately 12 inches 0 3 m 29 Place 6 64 x 10 x 10 inch 16 87 x 25 25 cm thick steel block under both wheels at the non steer end of the machine 30 Lower the machine onto the blocks Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS 31 Before serial number 41137 Raise the platform at least 12 feet 3 6 m Result ANSI and CSA models The tilt alarm will sound at 180 beeps per minute Result CE and Australian models The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted After serial number 41136 Raise the platform at least 12
330. ould 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 lifting jack under the drive chassis at the ground controls side of the machine 15 Raise the machine approximately 4 inches 10 cm Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS MODELS WITHOUT OUTRIGGERS PAIS NAA Level sensor models without outriggers chassis b level sensor 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 Section 4 Repair Procedures July 2007 GROUND CONTROLS 18 Raise the platform at least 12 feet 3 6 m O Result The tilt alarm does not sound and all functions will operate Proceed to step 20 W 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 th
331. ound and platform controls Turn the key switch to the off position 2 Remove the fasteners securing the lid of the platform controls and open the platform control box 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 52302 July 2007 Section 4 Repair Procedures REV C PLATFORM CONTROLS 3 Rotate the platform control box in the position shown to correctly identify the c
332. out 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 FUE Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION 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 Section 4 Repair Procedures July 2007 Platform Controls The platform controls used to activate machine VA functions from the platform or while standing on the N ground contain a printed circuit board joystick decal membrane pad butt
333. perly supported when removed from the machine Part No 52302 July 2007 Section 4 Repair Procedures REV C 3 3 Wear Pads How to Replace the Scissor Arm Wear Pads 1 Remove the platform See 2 1 How to Remove the Platform 2 Remove the mounting fasteners from the stationary wear pads on the platform Note Pay attention to the position of the wear pads before they are removed so when the new ones are installed they will be in the correct position 3 Connectthe platform controls to the quick disconnect plug to allow the machine to operate 4 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine 5 Raise the platform approximately 10 feet 3 m 6 Liftthe safety arm move it to the center of the scissor arm and rotate down to a vertical position 7 Lower the scissor arms onto the safety arm AWARNING Crushing hazard Keep hands clear of the safety arm when lowering the scissor arms Part No 52302 Genie GS 2668 RT GS 3268 RT SCISSOR COMPONENTS 8 Turn the key switch to the off position and push in the red Emergency Stop buttons to the off position at both the ground and platform controls 9 Secure both ends of the scissor arms together with a strap or other suitable device 10 Attach a strap from an overhead crane to the non steer end of the scissor arms 11 Raise the scissor
334. 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 Pushin the red Emergency Stop button to the off position O Result The engine should shut off and no machine functions should operate Start the engine from platform controls Push in the red Emergency Stop button to the off position O 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 Part No 52302 July 2007 Section Scheduled Maintenance Procedures ppom M 1 REV D 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
335. 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 AWARNING Electrocution 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 Tagand disconnect the wiring from the coil to be tested 2 Testthe coil resistance using a multimeter set to resistance Q 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 Genie GS 2668 RT GS 3268 RT REV D 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
336. que drive Result MAX HIGH TORQUE DRIVE is showing in the diagnostic display window Press the lift function enable button 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 Press the lift function enable button 10 Push in the red Emergency Stop button to the Genio cha off position at the ground controls 4 46 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 4 Repair Procedures REV D Models with software revision or higher 1 Pull out the red Emergency Stop button to the on position at the platform controls 2 Pushin 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 FWD HIGH TORQUE DRIVE is showing in the diagnostic display window 7 Pressthe lift function enable button Press the yellow platform down button to decrease the drive speed or press the blue platform up button to increase the drive speed
337. r 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 Part No 52302 July 2007 Section Scheduled Maintenance Procedures REV C CHECKLIST PROCEDURES 4 5 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 DF750 Operator s Manual Kubota part number EG261 8916 1 OR the Kubota DF752 Operator s Manual Kubota part number EG601 8916 1 OR the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Kubota DF750 Operator s Manual Inspect the Engine Air Filter 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 pe
338. r 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 D905 Operator s Manual Kubota part number 16622 8916 5 OR the Perkins 403C 11 User s Handbook Perkins part number 100816460 Kubota D905 Operator s Manual REV A 12 Perform Engine Maintenance Kubota D905 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 D905 Operator s Manual Kubota part number 16622 8916 5 Kubota D905 Operator s Manual Genie part number 84240 Genie part number 84240 Perkins 403C 11 User s Handbook Genie part number 97360 Genie GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section Scheduled Maintenance Procedures Checklist B Procedures REV D 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 AWARNING Electrocution hazard Contact with electrically charged circuits cou
339. r 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 Checkto 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 Part No 52302 Genie GS 2668 RT GS 3268 RT 3 7 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage
340. r the machine and remove the jack Part No 52302 July 2007 Section 4 Repair Procedures REV D Confirm the front to back level sensor setting 42 Center a lifting jack under the drive chassis at the steer end of the machine 43 Raise the machine approximately 6 inches 15 cm 44 Place a 4 08 x 10 x 10 inch 10 36 x 25 x 25 cm thick steel block under both wheels at the steer end of the machine 45 Lower the machine onto the blocks 46 Raise the platform at least 12 feet 3 6 m O 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 47 Lower the platform to the stowed position 48 Raise the machine slightly 49 Remove the blocks from under both wheels 50 Lower the machine and remove the jack 51 Center a lifting jack under the drive chassis at the non steer end of the machine 52 Raise the machine approximately 6 inches 15 cm Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS 53 Place a 4 08 x 10 x 10 inch 10 36 x 25 x 25 thick steel block under both wheels
341. raulic hoses on the pump AWARNING 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 AWARNING replacing the hydraulic pump it is critical to return the lift speed and raised drive speed settings to original factory specifications Refer to Maintenance Procedure B 11 Test the Drive Speed Raised Position to check the speeds and see Repair Procedure 1 3 Controller Adjustments to correct the raised drive speed percentage settings Genie RUN HYDRAULIC PUMP How to Prime the Pump Component damage hazard Be sure that the hydraulic tank shutoff valves if equipped are in the open position before priming the pump The engine must not be started with the hydraulic tank shutoff valves in the closed position or component damage will occur Connect a 0 to 600 psi 0 to 50 bar pressure gauge to either diagnostic test port on the function manifold 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 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 Discon
342. rectional valve M Proportional solenoid valve 9 Shuttle valve GS 2668 RT GS 3268 RT Section 6 Schematics July 2007 Hydraulic Schematic before serial number 35557 REV C Part 1 of 2 OUTRIGGERS GENERATOR OPTION OPTION xod imum 7 A 68 11 Bras LEFT 1 RIGHT 1 d Soops FRONT 206 8 bar f OUTRIGGER OUTRIGGER lm _ 1 C2 COUNTERBALANCE EL MANIFOLD STEER CYLINDER Q 1 TEST1 TEST2 LEFT 3 p RIGHT put OUTRIGGER OUTRIGGER JE OUTRIGGER XI Y4 vaa C Mt ba 0 063 in t BB m E 1 6 i Y40 Ne ARE BD rx L T bar AE 2000 psi i 1878bar i Ny ji td
343. res may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine Injection system REV D Injection pump make Bosch MD Injection timing 13 to 25 BTDC Injection pump pressure Fuel requirement 1991 psi 137 bar diesel number 2 D Battery Type 12V DC Group 34 78 Quantity 1 Ampere hour 75AH Cold cranking ampere 900A Reserve capacity 25A rate 125 minutes Starter motor Brush length new 0 5188 in 13 mm Brush length minimum 0 3346 in 8 5mm Alternator Output 30A 14V DC Fan belt deflection 1 4 to 3 8 inch 7to9mm Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie A TEREX COMPANY 2 4 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 2 Specifications REV D Kubota D905 Engine Tier 2 after serial number GS6805 43885 Displacement Number of cylinders Bore and stroke Horsepower net intermittent Firing order Compression ratio Compression pressure Low idle High idle Governor Valve clearance cold 54 86 cu in 0 898 liters 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 1500 rpm 300 hz 3000 rpm 600 hz centrifugal mechanical 0 0057 to 0 0072 in 0 145 to 0 185 mm Engine coo
344. rformance and component damage Perform this procedure with the engine off 1 Kubota D905 models Pull up on the engine tray locking pin located under the radiator on the engine pivot tray Swing the engine pivot tray out and away from the machine for access 2 Kubota D905 models Remove the wingnut securing the end cap to the air cleaner canister i 7 Genie part number 97359 Remove the end cap Kubota DF752 Operator s Manual All other models Disconnect the retaining Genie part number 84250 clamps securing the end cap to the air cleaner canister Remove the end cap Kubota D905 Operator s Manual ps Genie part number 84240 Remove the air filter element 4 Clean the inside of the air filter canister and the erkins 11 User s Handboo k h loth Genio number 97360 canister gasket with a damp clot 5 Inspect for and remove any blockage or debris from the intake air passages Genie Part No 52302 GS 2668 RT GS 3268 RT Section 3 Scheduled Maintenance Procedures July 2007 CHECKLIST A PROCEDURES 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 en
345. roll to motion alarm Result MOTION ALARM is showing in the diagnostic display window 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 Part No 52302 July 2007 Section 4 Repair Procedures REV D 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 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 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 orr position Models with software revisions EO DO or lower proceed to step 12 Models with software revisions FO and higher proce
346. rols Result The revision level of the ECM will appear in the LED display window Section 4 Repair Procedures July 2007 GROUND CONTROLS How to Adjust the Stowed Drive Speed ADANGER 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 Note On machines with software revision B1 or lower stowed drive speeds in forward and reverse are simultaneously adjusted resulting in both directions of travel operating at the same speed On machines with software revision CO or higher the stowed forward drive speed and the stowed reverse drive speed may be adjusted independent of one another See 7 2 How to Determine the Revision Level Models with software revision B1 or lower 1 Pull out the red Emergency Stop button to the on position at the platform controls 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 Genie GS 2668 RT GS 3268 RT REV D diagnostic display blue platform up button lift function enable button yellow platform down button Result TUN
347. roportional coil Y51 fault Drive forward function disabled Troubleshoot coil OR wiring COIL FAULT 93 Drive pump reverse m DRIVE REV PROP Red proportional coil Y51 fault Drive reverse function disabled Troubleshoot coil OR wiring COIL FAULT MACHINE TYPE Red Wrong machine type selected Machine will not operate Correct selection FAULT Part No 52302 enie A TEREX COMPANY GS 2668 RT GS 3268 RT Section 5 Fault Codes July 2007 E This page intentionally left blank Genie 5 12 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics Observe and Obey Electrocution hazard Contact with AWARNING electrically charged circuits could M Troubleshooting and repair procedures shall be result in death or serious injury completed by a person trained and qualified on Remove all rings watches and the repair of this machine other jewelry Immediately tag and remove from service a Hydraulic Schematics damaged or malfunctioning machine AWARNING Bodily injury hazard Spraying M Repair any machine damage or malfunction hydraulic oil can penetrate and before operating the machine burn skin Loosen hydraulic connections very slowly to allow Before Troubleshooting the oil
348. s 4 2 d B Wi FUNCTION 2935 MANIFOLD e e E 6 5 gpm 6 5 gpm 24 6 L min 24 6 L min POO 9 gt HYDRAULIC TANK HS0032B HS0027J Genio 6 100 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Hydraulic Schematic REV before serial number 35557 Part 2 of 2 PLATFORM 89007 Dum OVERLOAD A MANIFOLD OPTION AK i em Y7 Y10 ae S GS 3268 1 1 Ho XQ a Y7A ay O INI E eur dua 4B li 1 1 168 LJ E LA TN 1 M ya Siei 4 9 DYNAMIC BRAKING ps AA AC ON MODELS WITH M 2 1 DYNAMIC BRAKING gt lt a Ox I hi Y1B 0 035 241 3 0 89 Ww x 5 psi i 0 35 bar Ke E 2800 psi 193 FUNCTION rc bar MANIFOLD ee ESSERE IE
349. s For oil requirements refer to the Capacity 3 1 quarts Engine Operator Handbook on your machine 2 9 liters Fuel pump Alternator Fuel pressure static 2 84 psi Output 30A 14V DC 0 19 bar Fan belt deflection 1 4 to 3 8 inch Fuel flow rate 0 125 gpm 7 to 9 mm 0 47 L min Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice Genie Part No 52302 TEREX COMPANY GS 2668 RT GS 3268 RT Section 2 Specifications July 2007 SPECIFICATIONS Kubota DF752 Engine Displacement 45 21 cu in 0 74 liters Number of cylinders 3 2 68 x 2 68 inches 68 x 68 mm Bore amp stroke Horsepower Gross intermittent 24 8 3600 rpm 18 5 kW 3600 rpm Firing order 1 2 3 Low idle 1500 rpm 300 hz High idle 3200 rpm 640 hz Governor centrifugal ball mechanical Compression ratio 9 2 1 Compression pressure 128 to 185 psi 8 8 to 12 7 bar 0 0057 to 0 0072 inches 0 145 to 0 185 mm Valve clearances cold Lubrication system Oil pressure 28 to 64 psi operating temperature 3850 rpm 1 9 to 4 4 bar Oil capacity including filter 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 2 84 psi 0 19 bar Fuel flow rat
350. section of the pump 1 Connecta 0 to 5000 psi 0 to 350 bar pressure gauge to test port 2 item J and test port 1 item 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 Models without outriggers Start the engine from platform controls and press the high torque button BN6 Models with outriggers Start the engine from platform controls and press the high torque left front outrigger button BN17 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 O or P1 system relief valve item and remove the Genie GS 2668 RT GS 3268 RT REV D Q w od 1 SN c 2 6 DA a system relief valve b test port 1 C test port 2 d P2 system relief valve 7 Adjustthe internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap ADANGER Tip over hazard Failure to adjust the relief valve as instructed will cause the machine to tip over resulting in death or serious injury Do not adjust the relief valve higher than specified 8 Repeat steps 4 through 5 to confirm the relief val
351. sition at the ground controls Result TUNE is showing in the diagnostic display window 52 Use the yellow platform down arrow to scroll to select options Result SELECT 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 Part No 52302 Genie GS 2668 RT GS 3268 RT PLATFORM OVERLOAD COMPONENTS 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 Rota
352. steners Slide the outrigger cylinder away from the machine Crushing hazard The outrigger ACAUTION 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 REVA Part No 52302 July 2007 Section 4 Repair Procedures Brake Release Hand Pump Components REV B 14 1 Brake Release Hand Pump Components Before serial number 41200 The brake release hand pump manifold is mounted underneath the battery in the hydraulic tray After serial number 41199 The brake release hand pump manifold is mounted at the non steer end of the chassis on the ground controls side of the machine Index Schematic No Description Item Function Torque 1 Shuttle valve AE Brake release circuit 45 50 in lbs 5 Nm 2 Check valve pilot operated uie Manual brake release circuit 65 70 in lbs 7 8 Nm 3 Hand pump Aiit Manual brake release 30 ft lbs 41 Nm 4 Needle valve Manual brake release enable 45 50 in lbs 5 Nm Note alpha callouts refer to corresponding notes on the hydraulic schematic After serial number GS6804 43183 Genie Part
353. switch settings located on the circuit board inside the platform control box DIP switches have two positions on or off When reading the DIP switch code in the DIP Switch Codes Chart on the next page the on and off are represented by the numbers 1 on and O off How to Determine the DIP Switch Configuration 1 Turn the key switch to ground control and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls 2 Move and hold the platform up down toggle switch in the up direction and activate the function enable toggle switch from the ground controls O Result The diagnostic display window located on the ground control panel will display a configuration number without the dot illuminated This configuration number indicates the current configuration of the machine Note Configuration code that is less than 100 will be shown as a constant display Configuration code that is greater than 99 will be shown as a flashing display Genie GS 2668 RT GS 3268 RT REV How to Configure the Software Note If replacing the circuit board note the position of each of the 8 toggle switches on the DIP switch block Set the DIP switch on the new circuit board to the same configuration of the old one Note If replacing the circuit board use dielectric grease on the DIP switch and all plug in connectors 1 Pushin the red Emergency Stop button to the off position at both the gr
354. t wr 5 9 3 3 rm 9 2 z E 858 5 d m 28 5 A v 5 9 55 2 2 5 20 20 3 Z 2G E m I gt 2 d c lt lt 1 SE 8359 5 g SiS 2 g 9 m 52 g E lt E lt F 5 2 m o a m 2 gt 2 5 2 5 3 z MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF T Genie A TEREX COMPANY 6 42 GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 6 Schematics REV B Electrical Schematic CE Models with Gasoline LPG Power from serial number GS6805 43595 to GS6805 44168 Part 2 of 3 CR8 TERMINAL 30 ABZ BATTERY 8 aul WT No 4 20A i 1 17 jo oo E tr de HYDRAULIC 112 OIL COOLER OPTION SENSOR MODELS WITHOUT BATTERY OUTRIGGERS 23 M1 G7 LEVEL wu t rs c 2 05 ELECTRONIC CONTROL MODULE 5 5 s lt c e ee 28 Loi gt F 5 S 9 9 5 o zi
355. t or is activated when the keyswitch is turned on Platform controls platform up down toggle switch fault or is activated when the keyswitch is turned on Platform controls platform up down fast speed function enable button fault or is activated when the key switch is turned on Platform controls platform up down slow speed function enable button fault or is activated when the keyswitch is turned on Platform controls function enable switch fault or is activated when the key switch is turned on Platform controls joystick fault or is activated when the keyswitch is turned on REV B Check for stuck steer microswitch OR test or replace the steer microswitch Check for stuck toggle switch OR test or replace the toggle switch Check for stuck function enable button OR test or replace the platform up down fast speed function enable button Check for stuck function enable button OR test or replace the platform up down slow speed function enable button Check for stuck function enable switch OR check for function enable switch being tied down OR test or replace the platform up down slow speed function enable button Check to make sure the joystick is in the center or neutral position Genie COMPANY GS 2668 RT GS 3268 RT Part No 52302 July 2007 Section 5 Fault Codes REV B No power output from ECM to the steer right valve coil OR ECM does no
356. t 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 Part No 52302 Genie GS 2668 RT GS 3268 RT SCISSOR COMPONENTS 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 AWARNING 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 AWARNING 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 AWARNING inner arm index 10 could become unbalanced and fall if not properly supporte
357. t sense the steer right valve coil No power output from ECM to the steer left valve coil OR ECM does not sense the steer left valve coil No power output from ECM to the platform up valve coil OR ECM does not sense the platform up valve coil No power output from ECM to the brake valve coil OR ECM does not sense the brake valve coil No power output from ECM to the right front and left rear drive forward valve coil OR ECM does not sense the right front and left rear drive forward valve coil No power output from ECM to the right front and left rear drive reverse valve coil OR ECM does not sense the right front and left rear drive reverse valve coil Machine will not steer right Machine will not steer left Platform will not raise Machine will not drive Machine will not drive forward Machine will not drive in reverse Genie Part No 52302 FAULT CODE CHART BEFORE SERIAL NUMBER GS6803 42382 No power output from ECM to steer right coil schematic item R OR bad valve coil No power output from ECM to steer left coil schematic item R OR bad valve coil No power output from ECM to platform up coil schematic item P OR bad valve coil No power output from ECM to brake coil schematic item T OR bad valve coil No power output from ECM to right front and left rear drive forward valve coil schematic item A OR bad valve coil No power output from ECM to right
358. te the result 2 Pushin 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 is showing in the diagnostic display window diagnostic display blue platform up button lift function enable button yellow platform down button Part No 52302 Genie GS 2668 RT GS 3268 RT 4 51 GROUND CONTROLS Machine Option Definitions Descent Delay This option halts descent at approximately 12 feet 3 6 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
359. te 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 Section 4 Repair Procedures July 2007 PLATFORM OVERLOAD COMPONENTS 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 TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM CONDITION POSSIBLE CAUSE 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 LOWER THE UP LIMIT SWITCH SLIGHTLY ADJUSTMENT OR FAULTY OR REPLACE CONTACTS
360. temperature switch LOW ECU Red Low ECM voltage System shutdown Charge battery VOLTAGE 69 Consult Genie Industries Service LOW ENGINE Red Low RPM Engine idle RPM too low Department RPM 70 3 Consult Genie Industries Service HIGH ENGINE Red High RPM Engine RPM too high Department RPM 80 Left front outrigger coil Y35 LEFT FRONT Red fault Left front outrigger disabled Troubleshoot coil OR wiring OTRG COIL FLT 81 Left rear outrigger coil Y33 i LEFT REAR OTRG Red fault Left rear outrigger disabled Troubleshoot coil OR wiring COIL FLT 82 Right front outrigger coil Y36 T RIGHT FRONT Red fault Right front outrigger disabled Troubleshoot coil OR wiring OTRG COIL FLT 83 Right rear outrigger coil Y34 22 RIGHT REAR Red tut 99 Right rear outrigger disabled Troubleshoot coil OR wiring OTRG COIL FLT 84 Outrigger extend coil Y40 i OUTRIGGER EXT Red fault Outrigger extend function disabled Troubleshoot coil OR wiring COIL FLT 85 Outrigger retract coil Y39 T OUTRIGGER RET Red fault Outrigger retract function disabled Troubleshoot coil OR wiring COIL FLT 86 Outrigger slowdown coil Y44 Outrigger slow extend function OUTRIGGER Red fault disabled Troubleshoot coil OR wiring SLOW COIL FLT 2 SPEED COIL Red 2 speed coil Y1 fault High torque drive function disabled Troubleshoot coil OR wiring FAULT 92 Drive pump forward 4 2 DRIVE FWD PROP Red p
361. ten the retaining fasteners Do not over tighten Section 4 Repair Procedures July 2007 GROUND CONTROLS 7 5 Level Sensor Models without Outriggers after serial number 41753 The Electronic Control Module ECM is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor 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 77 7777777 hazard Failure to install ADANGER 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 Liftthe safety arm move to the center of the scissor arm and rotate to a vertical position Genie GS 2668 RT GS 3268 RT REV D 4 Lower the platform onto the safety arm AWARNING 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
362. the Kubota D905 Operator s Manual Kubota part number 16622 8916 5 OR the Kubota DF750 Operator s Manual Kubota part number EG261 8916 1 Kubota D905 Operator s Manual Genie part number 84240 Genie part number 84240 Perkins 403C 11 User s Handbook Kubota DF750 Operator s Manual Genie part number 97360 Genie part number 97359 Genie Part No 52302 GS 2668 RT GS 3268 RT 3 29 Section 3 Scheduled Maintenance Procedures July 2007 Checklist D Procedures 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 REVC Measure the thickness of each platform scissor arm wear pad at the steer end of the machine Result The measurement
363. the hydraulic oil level is within the top 2 inches 5 cm of the sight gauge 1 Disconnect all electrical tools from the machine 2 Startthe engine from the platform controls 3 Press the generator select switch Result The generator should activate and the engine should go to high rpm Part No 52302 Genie bebe MANIFOLDS 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 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 Turn the key switch to the off position Use a wrench to hold the generator flow regulator valve item DB and remove the cap 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 Repeat steps 2 through 5 to confirm the generator AC voltage GS 2668 RT GS 3268 RT 4 83 Section 4 Repair Procedures July 2007 MANIFOLDS 9 7 Valve Coils How to Test a Coil A
364. the top of each adjusting nut 16 Disconnect the positive lead Adjust the front to back axis 17 Without disconnecting the wire harness from the level sensor connect the positive lead of the multimeter to the blue wire at the level sensor 18 Adjust the X axis front to back to 2 43V DC Tap the top of the level sensor lightly with fingers after each turn of an adjusting nut ADANGER 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 Part No 52302 Genie GS 2668 RT GS 3268 RT GROUND CONTROLS 19 Disconnect the positive and negative leads 20 Apply Sentry Seal to the adjusting nuts 21 Push in the red Emergency Stop button to the off position at the platform controls 22 Before serial number GS6803 42382 Press and hold the outrigger enable button and press and hold the auto level button and pull out the red Emergency Stop button to the on position at the platform controls Continue to hold the outrigger enable button and the auto level button for approximately 3 seconds or until a beep is heard Release the buttons After serial number GS6803 42381 Press and hold the auto level button and press and
365. the yoke and drive motor assembly from the machine Crushing hazard The yoke and ACAUTION 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 Part No 52302 July 2007 Section 4 Repair Procedures REVA 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 Blockthe 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 AWARNING 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 AWARNING hydraulic oil can p
366. thin the top 2 inches 5 cm of the sight gauge 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to test port 1 item 1 on the function manifold Place the maximum rated load in the platform Secure the load to the platform Refer to Section 2 Specifications 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 from the ground controls Press and hold the function enable switch and hold the platform up down toggle switch in the up direction Allow the platform to raise completely then continue holding the switch while observing the pressure reading on the pressure gauge Note the pressure Refer to Section 2 Specifications Turn the engine off Hold the lift relief valve with a wrench and remove the cap item K Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap ADANGER Tip over hazard Failure to adjust 8 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 Repeat steps 4 through 5 to confirm the relief valve pressure Genio cha REV D Dp amp w 1 Op 3 Y m 5 J 3 3 P SY 2 N L SS M a test port 1 b relief valve GS 2668 RT GS 32
367. tics July 2007 Electrical Schematic ANSI Models with Diesel Power from serial number GS6803 42382 to GS6805 43594 Part 3 of 3 REVA QD4 QD3 P2 Q EMERGENCY WH RD 4 4 4 BK POWER TO PLATFORM STOP RD WH 7 Rb POWER ro GROUND 2 31 BL 1 1 1 1 WH GROUND BK r 2 2 2 2 BL DATALINK HIGH OR 5 5 1 1 5 5 5 1 OR DATA LINK LOW 1 OUTRIGGERS OPTION J5 PIN2 2 D7 PLATFORM CONTROLS VOLTAGE cipio PRINTED CIRCUIT BOARD REGULATOR S8 2 TILT LEVEL J2 PIN1 SENSOR a YL HALL EFFECT 9 7 ERATOE JC1 9 I 9 42 PIN12 JOYSTICK 1812 1813 1814 1815 4 8 e CONTROLLER n0 9 J2PIN13 O LF RF LR RR m
368. to a coil Faulty diodes can fail to protect the electrical system resulting in a tripped circuit breaker or component damage AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Testthe coil for resistance See 9 3 How to Test a Coil 2 Connect a 100 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 100 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 Part No 52302 Genie GS 2668 RT GS 3268 RT 100 9 RESISTOR possesses soe 4 9 TA ae d bap by I 1 1 L 4 WOM OV a multimeter b 9VDOC battery 10Q resistor d Note Dotted lines in illustration indicate 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 Atthe
369. 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 Note 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 AWARNING 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 AWARNING Crushing hazard The cylinder could fall if not properly supported when the pin is removed Section 4 Repair Procedures July 2007 SCISSOR COMPONENTS 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 AWARNING inner ar
370. unction 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 Section 4 Repair Procedures July 2007 GROUND CONTROLS How to Adjust the Lift Speed 1 Pull out the red Emergency Stop button to the on position at the platform controls Push in the red Emergency Stop button to the off position at the ground controls 3 Turn the key switch to ground control 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 Press the lift function enable button Use the yellow platform
371. unction 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 ourniccEns orr 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 oPrioNs is showing in the diagnostic display window 20 Push in the red Emergency Stop button to the off position at the ground controls Section 4 Repair Procedures SSS mc GROUND CONTROLS CE models with all software revisions 1 C7 5 ji fn C9 d Moa 2 7 a diagnostic display b blue platform up button c lift function enable button d yellow platform down button 4 Use the yellow platform down arrow to scroll to 8 select options Result SELECT oPrioNs is showing in the diagnostic display window The ECM is now in programming mode Genio Turn the key switch to groun
372. ve pressures Part No 52302 July 2007 Section 4 Repair Procedures REV D How to Adjust the Steer Relief Valve 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to test port 2 item J on the function manifold 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 Startthe engine from the platform controls 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 Turn the engine off Use a wrench to hold the steer relief valve and remove the cap item V 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 Repeat steps 3 through 4 to confirm the relief valve pressure Part No 52302 Genie GS 2668 RT GS 3268 RT 4 77 MANIFOLDS x Y 1 w AAA test port 2 b steer relief valve Section 4 Repair Procedures July 2007 MANIFOLDS How to Adjust the Lift Relief Valve Note Be sure that the hydraulic oil level is wi
373. y cause component damage AWARNING Electrocution hazard Contact with hot or live circuits may result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires 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 Genio REV D 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 AWARNING 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 52302 July 200
374. z B gt z MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF A Genie A TEREX COMPANY 6 34 GS 2668 GS 3268 RT Part No 52302 July 2007 Section 6 Schematics Electrical Schematic REV A ANSI Models with Gasoline LPG Power from serial number GS6805 43595 to GS6805 44770 Part 2 of 3 f CR8 TERMINAL 30 ABZ BATTERY UM E E T TS e ote HYDRAULIC i f OILCOOLER m M 87 MODELS WITHOUT BATTERY __QUTRIGGERS 623 BK 489919 de c 2 05 ELECTRONIC CONTROL MODULE 5 5 S s T T 4 t 4 amp 5 5 OE gt 9 9 5 o zi 5 5 8 9 m S 9 22 ABI 7 1 Y4 Y1 Y1B Y6 Y6A Y9 Q2 Q1 E X 4 X 4 X EX X LY 7 2 S 7 T Sa L x EXP EX 0 4 M SW2 SW1 5 FB1 1 Y2 Y5 Y5A Y29 9 3 Se Ss gt o o gt w gm gt gt

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