Service Manual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · in this...
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Part No. 52302
Rev D
March 2005
Service Manual
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March 2005
GS-2668 RT • GS-3268 RT Part No. 52302ii
Important
Read, understand and obey the safety rules andoperating instructions in the appropriate Operator'sManual on your machine before attempting anymaintenance procedure.
Basic mechanical, hydraulic and electricalskills are required to perform most procedures.However, several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized Genie dealerservice center.
Technical Publications
Genie Industries has endeavored to deliver thehighest degree of accuracy possible. However,continuous improvement of our products is a Geniepolicy. Therefore, product specificationsare subject to change without notice.
Readers are encouraged to notify Genie of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other manuals.
Copyright © 1998 by Genie Industries
52302 Rev D March 2005First Edition, Fourth Printing
"Genie" is a registered trademark of GenieIndustries in the USA and many other countries."GS" is a trademark of Genie Industries.
Printed on recycled paper
Printed in U.S.A.
Contact Us:
www.genieindustries.come-mail: [email protected]
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March 2005
Part No. 52302 GS-2668 RT • GS-3268 RT iii
DangerFailure to obey the instructions and safety rulesin this manual and the appropriate Operator'sManual on your machine will result in death orserious injury.
Many of the hazards identified in theoperator’s manual are also safety hazardswhen maintenance and repair proceduresare performed.
Do Not Perform MaintenanceUnless:
You are trained and qualified to performmaintenance 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, liftingequipment and a suitable workshop.
Safety Rules
Section 1 • Safety Rules
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March 2005
GS-2668 RT • GS-3268 RT Part No. 52302
SAFETY RULES
Personal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top priority.
Read each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Red—used to indicate thepresence of an imminentlyhazardous situation which, if notavoided, will result in death orserious injury.
Orange—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, could result in death orserious injury.
Yellow with safety alert symbol—used to indicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Yellow without safety alertsymbol—used to indicate thepresence of a potentiallyhazardous situation which, if notavoided, may result in propertydamage.
Green—used to indicate operationor maintenance information.
Be sure to wear protective eye wear andother protective clothing if the situationwarrants it.
Be aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting or
placing loads. Always wear approved steel-toedshoes.
Workplace SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gases
and engine fuels. Always have an approved fireextinguisher within easy reach.
Be sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free of
debris that could get into machine components andcause damage.
Be sure that your workshop or work areais properly ventilated and well lit.
Be sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing the
weight to be lifted. Use only chains or straps thatare in good condition and of ample capacity.
Be sure that fasteners intended for onetime use (i.e., cotter pins and self-lockingnuts) are not reused. These componentsmay fail if they are used a second time.
Be sure to properly dispose of old oil or otherfluids. Use an approved container. Please beenvironmentally safe .
iv
Section 1 • Safety Rules
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March 2005
Part No. 52302 GS-2668 RT • GS-3268 RT
Table of Contents
Introduction
Important Information ......................................................................................... ii
Section 1 Safety Rules
General Safety Rules ........................................................................................ iii
Section 2 Rev Specifications
B Machine Specifications ................................................................................ 2 - 1
B Performance Specifications ......................................................................... 2 - 2
B Hydraulic Specifications ............................................................................... 2 - 2
B Manifold Component Specifications ............................................................. 2 - 3
B Kubota D905 Engine .................................................................................... 2 - 4
B Perkins 403C-11 Engine .............................................................................. 2 - 5
B Kubota DF750 Engine ................................................................................. 2 - 6
B Kubota DF752 Engine ................................................................................. 2 - 7
B Hydraulic Hose and Fitting Torque Specifications ........................................ 2 - 8
Section 3 Rev Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................. 3 - 3
Maintenance Inspection Report ................................................................... 3 - 5
B Checklist A Procedures
A-1 Perform Pre-operation Inspection ....................................................... 3 - 7
A-2 Perform Function Tests ...................................................................... 3 - 7
A-3 Perform Engine Maintenance ............................................................. 3 - 8
A-4 Inspect the Engine Air Filter ................................................................ 3 - 8
A-5 Perform 30 Day Service ..................................................................... 3 - 9
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March 2005
GS-2668 RT • GS-3268 RT Part No. 52302
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued
B Checklist A Procedures, continued
A-6 Perform Engine Maintenance - Kubota D905 Models ....................... 3 - 10
A-7 Perform Engine Maintenance - Kubota Models ................................ 3 - 10
A-8 Perform Engine Maintenance - Kubota Models ................................ 3 - 11
A-9 Perform Engine Maintenance - Kubota Models ................................ 3 - 11
A-10 Drain the Fuel Filter/Water Separator - Diesel Models ...................... 3 - 12
A-11 Perform Engine Maintenance - Kubota D905 Models ....................... 3 - 13
B Checklist B Procedures
B-1 Inspect the Battery ........................................................................... 3 - 14
B-2 Inspect the Electrical Wiring ............................................................. 3 - 15
B-3 Inspect the Tires and Wheels(including castle nut and lug bolt torque) .......................................... 3 - 16
B-4 Perform Engine Maintenance - Perkins 403C-11 Models ................. 3 - 16
B-5 Test the Key Switch .......................................................................... 3 - 17
B-6 Test the Emergency Stop ................................................................. 3 - 17
B-7 Test the Automotive-style Horn ........................................................ 3 - 18
B-8 Test the Fuel Select Operation - Gasoline/LPG Models ................... 3 - 19
B-9 Test the Drive Brakes ....................................................................... 3 - 20
B-10 Test the Drive Speed - Stowed Position ........................................... 3 - 21
B-11 Test the Drive Speed - Raised Position ............................................ 3 - 22
B-12 Inspect the Fuel and Hydraulic Tank Cap Venting Systems ............. 3 - 23
B-13 Perform Hydraulic Oil Analysis ......................................................... 3 - 24
B-14 Test the Flashing Beacons (if equipped) .......................................... 3 - 24
B-15 Perform Engine Maintenance - Kubota D905 Models ....................... 3 - 24
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March 2005
Part No. 52302 GS-2668 RT • GS-3268 RT
TABLE OF CONTENTS
Section 3 Rev Scheduled Maintenance Procedures, continued
B Checklist C Procedures
C-1 Grease the Platform Overload Mechanism (if equipped) .................. 3 - 25
C-2 Clean the Fuel Tank - Diesel Models ............................................... 3 - 26
C-3 Replace the Hydraulic Tank Breather Cap - Models withOptional Hydraulic Oil ....................................................................... 3 - 27
C-4 Perform Engine Maintenance - Diesel Models .................................. 3 - 27
C-5 Perform Engine Maintenance - Kubota D905 and DF750 Models .... 3 - 27
B Checklist D Procedures
D-1 Check the Scissor Arm Wear Pads .................................................. 3 - 28
D-2 Calibrate the Platform Overload System (if equipped) ...................... 3 - 29
D-3 Replace the Hydraulic Tank Return Filter ......................................... 3 - 36
D-4 Perform Engine Maintenance - Perkins 403C-11 Models ................. 3 - 37
D-5 Perform Engine Maintenance - Kubota DF752 Models ..................... 3 - 37
D-6 Perform Engine Maintenance - Kubota Models ................................ 3 - 37
D-7 Perform Engine Maintenance - Kubota D905 Models ....................... 3 - 37
B Checklist E Procedures
E-1 Test or Replace the Hydraulic Oil ..................................................... 3 - 38
E-2 Perform Engine Maintenance - Perkins 403C-11 Models ................. 3 - 39
E-3 Perform Engine Maintenance - Gasoline/LPG Models...................... 3 - 40
E-4 Perform Engine Maintenance - Perkins 403C-11 Models ................. 3 - 40
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March 2005
GS-2668 RT • GS-3268 RT Part No. 52302
Section 4 Rev Repair Procedures
Introduction .................................................................................................. 4 - 1
B Platform Controls
1-1 Circuit Boards .................................................................................... 4 - 2
1-2 Joystick Controller .............................................................................. 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 Platform ........................................................................................... 4 - 14
2-2 Platform Extension ........................................................................... 4 - 15
B Scissor Components
3-1 Scissor Assembly, GS-2668 RT ....................................................... 4 - 18
3-2 Scissor Assembly, GS-3268 RT ....................................................... 4 - 24
3-3 Wear Pads ....................................................................................... 4 - 31
3-4 Lift Cylinder(s) .................................................................................. 4 - 32
B Kubota D905 Engine
4-1 Timing Adjustment ........................................................................... 4 - 35
4-2 Glow Plugs ....................................................................................... 4 - 35
4-3 Engine RPM ..................................................................................... 4 - 35
4-4 Flex Plate ......................................................................................... 4 - 36
4-5 Coolant Temperature and Oil Pressure Switches ............................. 4 - 37
viii
TABLE OF CONTENTS
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March 2005
Part No. 52302 GS-2668 RT • GS-3268 RT
Section 4 Rev Repair Procedures, continued
B Kubota DF750 / DF752 Engine
5-1 Timing Adjustment ........................................................................... 4 - 38
5-2 Carburetor Adjustment - Gasoline/LPG Models ............................... 4 - 38
5-3 Choke Adjustment - Gasoline/LPG Models ...................................... 4 - 38
5-4 Flex Plate ......................................................................................... 4 - 38
5-5 Coolant Temperature and Oil Pressure Switches ............................. 4 - 38
5-6 Engine RPM ..................................................................................... 4 - 39
A Perkins 403C-11 Engine
6-1 Engine RPM ..................................................................................... 4 - 40
6-2 Timing Adjustment ........................................................................... 4 - 40
6-3 Flex Plate ......................................................................................... 4 - 41
6-4 Coolant Temperature and Oil Pressure Switches ............................. 4 - 41
B Ground Controls
7-1 Auxiliary Platform Lowering .............................................................. 4 - 42
7-2 Function Speed Tuning (after serial number GS6803-42381) .......... 4 - 43
7-3 Software Configuration (after serial number GS6803-42381) ........... 4 - 51
7-4 Level Sensor - Models without Outriggers(before serial number 41754) ........................................................... 4 - 55
7-5 Level Sensor - Models without Outriggers(after serial number 41753) .............................................................. 4 - 60
7-6 Level Sensor - Models with Outriggers............................................. 4 - 63
A Hydraulic Pump
8-1 Function Pump ................................................................................. 4 - 68
ix
TABLE OF CONTENTS
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March 2005
GS-2668 RT • GS-3268 RT Part No. 52302x
TABLE OF CONTENTS
Section 4 Rev Repair Procedures, continued
B Manifolds
9-1 Function Manifold Components ........................................................ 4 - 70
9-2 Valve Adjustments - Function Manifold ............................................ 4 - 74
9-3 Outrigger Manifold Components....................................................... 4 - 77
9-4 Valve Adjustments - Outrigger Manifold ........................................... 4 - 78
9-5 Generator Manifold Components ..................................................... 4 - 80
9-6 Valve Adjustments - Generator Manifold .......................................... 4 - 81
9-7 Valve Coils ....................................................................................... 4 - 82
B Fuel and Hydraulic Tanks
10-1 Fuel Tank ......................................................................................... 4 - 84
10-2 Hydraulic Tank ................................................................................. 4 - 85
A Steer Axle Components
11-1 Yoke and Drive Motor ...................................................................... 4 - 86
11-2 Steer Cylinder .................................................................................. 4 - 87
11-3 Tie Rod ............................................................................................ 4 - 88
A Non-steer Axle Components
12-1 Drive Motor and Brake ..................................................................... 4 - 89
A Outrigger Components
13-1 Outrigger Cylinder ............................................................................ 4 - 90
B Brake Release Hand Pump Components
14-1 Brake Release Hand Pump Components ......................................... 4 - 91
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March 2005
Part No. 52302 GS-2668 RT • GS-3268 RT xi
Section 5 Rev Fault Codes
Introduction .................................................................................................. 5 - 1
B Fault Code Chart (before serial number GS6803-42382) ............................ 5 - 3
A Fault Code Chart (after serial number GS6803-42381) ............................... 5 - 9
Section 6 Rev Schematics
Introduction .................................................................................................. 6 - 1
A Electronic Control Module Layout (before serial number GS6803-42382) ... 6 - 2
A Electronic Control Module Pin-Out Legend(before serial number GS6803-42382) ........................................................ 6 - 3
A Electronic Control Module Layout (after serial number GS6803-42381) ...... 6 - 4
A Electronic Control Module Pin-Out Legend(after serial number GS6803-42381) ........................................................... 6 - 5
A Wiring Diagram - Platform Control Box(before serial number GS6803-42382) ........................................................ 6 - 6
A Wiring Diagram - Platform Control Box(after serial number GS6803-42381) ........................................................... 6 - 7
A Electrical Schematics Abbreviation and Wire Color Legends ....................... 6 - 8
A Electrical Symbols Legend........................................................................... 6 - 9
B Electrical Schematic - Gasoline/LPG Models(before serial number 21161) ..................................................................... 6 - 10
B Electrical Schematic - Gasoline/LPG Models(from serial number 21161 to 21837) ......................................................... 6 - 12
B Electrical Schematic - Gasoline/LPG Models(from serial number 21838 to 38464) ......................................................... 6 - 14
B Electrical Schematic - Gasoline/LPG Models(from serial number 38465 to 41199) ......................................................... 6 - 18
B Electrical Schematic - Gasoline/LPG Models(from serial number 41200 to 41823) ......................................................... 6 - 22
A Electrical Schematic - Gasoline/LPG Models(from serial number 41824 to GS6803-42381) ........................................... 6 - 26
A Electrical Schematic - ANSI Models with Gasoline/LPG Power(from serial number GS6803-42382 to GS6805-43594) ............................ 6 - 30
A Electrical Schematic - ANSI Models with Gasoline/LPG Power(after serial number GS6805-43594) ......................................................... 6 - 34
TABLE OF CONTENTS
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March 2005
GS-2668 RT • GS-3268 RT Part No. 52302xii
TABLE OF CONTENTS
Section 6 Rev Schematics, continued
A Electrical Schematic - CE Models with Gasoline/LPG Power(from serial number GS6803-42382 to GS6805-43594) ............................ 6 - 38
A Electrical Schematic - CE Models with Gasoline/LPG Power(after serial number GS6805-43594) ......................................................... 6 - 42
B Electrical Schematic - Diesel Models(before serial number 21161) ..................................................................... 6 - 46
B Electrical Schematic - Diesel Models(from serial number 21161 to 21837) ......................................................... 6 - 48
B Electrical Schematic - Diesel Models(from serial number 21838 to 38464) ......................................................... 6 - 50
B Electrical Schematic - Diesel Models(from serial number 38465 to 40173) ......................................................... 6 - 54
B Electrical Schematic - Diesel Models(from serial number 40174 to 40939) ......................................................... 6 - 58
B Electrical Schematic - Diesel Models(from serial number 40940 to 41199) ......................................................... 6 - 62
B Electrical Schematic - Diesel Models(from serial number 41200 to 41823) ......................................................... 6 - 66
A Electrical Schematic - Diesel Models(from serial number 41824 to GS6803-42381) ........................................... 6 - 70
A Electrical Schematic - ANSI Models with Diesel Power(from serial number GS6803-42382 to GS6805-43594) ............................ 6 - 74
A Electrical Schematic - ANSI Models with Diesel Power(after serial number GS6805-43594) ......................................................... 6 - 78
A Electrical Schematic - CE Models with Diesel Power(from serial number GS6803-42382 to GS6805-43594) ............................ 6 - 82
A Electrical Schematic - CE Models with Diesel Power(after serial number GS6805-43594) ......................................................... 6 - 86
A Hydraulic Schematics Component Call-out Legend ................................... 6 - 90
A Hydraulic Symbols Legend ........................................................................ 6 - 91
B Hydraulic Schematic (before serial number 35557) ................................... 6 - 92
A Hydraulic Schematic (from serial number 35557 to 40484) ....................... 6 - 94
A Hydraulic Schematic (from serial number 40485 to GS6804-43183) ......... 6 - 96
A Hydraulic Schematic (after serial number GS6804-43183 ......................... 6 - 98
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March 2005 Section 2 • Specifications
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 2 - 1
Machine Specifications
Fluid Capacities (before serial number 42000)
Hydraulic tank 21.5 gallons81.4 liters
Hydraulic system (including tank) 25 gallons94.6 liters
Fuel tank 15 gallons56.8 liters
Fluid Capacities (after serial number 41999)
Hydraulic tank 15 gallons56.8 liters
Hydraulic system (including tank) 17 gallons64.4 liters
Fuel tank 14.5 gallons54.9 liters
Wheel alignment specification
Toe-in Measurement 0 ± 0.125 inch0 ± 3.2 mm
Tire and wheels
Wheel lugs 6 @ 1/2 -20
Lug bolt torque, dry 90 ft-lbs122 Nm
Lug bolt torque, lubricated 67.5 ft-lbs91.5 Nm
Castle nut torque, dry 300 ft-lbs406.7 Nm
Castle nut torque, lubricated 225 ft-lbs305 Nm
For operational specifications, refer to theOperator's Manual.
Rough Terrain, foam-filled
Tire size(before serial number 41200) 26 x 12 x 12(after serial number 41199) 26 x 12D380
Tire ply rating 8
Tire diameter 26 in66 cm
Tire width 12 in30 cm
Weight 178 lbs (+/- 7 lbs)80.7 kg (+/- 3.4 kg)
Non-marking, solid rubber
Tire size 22 x 16 x 9 in55.9 x 40.6 x 22.9 cm
Tire diameter 22 in55.9 cm
Tire width 9 in22.9 cm
Weight 120 lbs (+/- 1 lbs)54.4 kg (+/- 2.2 kg)
Industrial, foam-filled (before serial number 41200)
Tire size 24-12.00 x 12 in
Tire ply rating 8
Tire diameter 24 in61 cm
Tire width 12 in30 cm
Weight 165 lbs (+/- 7 lbs)74.8 kg (+/- 4.5 kg)
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
Specifications
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March 2005Section 2 • Specifications
REV B
2 - 2 GS-2668 RT • GS-3268 RT Part No. 52302
Performance Specifications
Drive speed, maximum
Platform stowed 3.8 mph6.1 km/h
40 ft / 7.2 sec12.2 m / 7.2 sec
Platform raised 0.5 mph0.8 km/h
40 ft / 54.6 sec12.2 m / 54.6 sec
Function speed, maximum from platform controls(with maximum rated load in platform)
GS-2668 RT
Platform up 28 to 32 secondsPlatform down 33 to 37 seconds
GS-3268 RT
Platform up 38 to 42 secondsPlatform down 35 to 39 seconds
Outrigger leveling, maximum
Front to back 6.6°Side to side 10.6°
Gradeability
GS-2668 RT 40%GS-3268 RT 35%
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
Hydraulic Specifications
Hydraulic Oil Specifications
Hydraulic oil type Chevron Rykon MV equivalentISO viscosity grade Multi-viscosityViscosity index 200
Cleanliness level, minimum 15/13
Water content, maximum 200 ppm
Chevron Rykon MV oil is fully compatible andmixable with Shell Donax TG (Dexron III) oils.Genie specifications require hydraulic oils which aredesigned to give maximum protection to hydraulicsystems, have the ability to perform over a widetemperature range, and have a minimum viscosity indexof 150. They should provide excellent antiwear,oxidation, corrosion inhibition, seal conditioning, andfoam and aeration suppression properties.
Optional fluids
Biodegradable Petro Canada Premium ECO 46Statoil Hydra Way Bio Pa 32
BP Biohyd SE-S
Fire resistant UCON Hydrolube HP-5046Quintolubric 822
Mineral based Shell Tellus T32Shell Tellus T46
Chevron Aviation A
Use Chevron Aviation A hydraulicoil when in ambient temperaturesconsistently below 32°F / 0°C.
Use Shell Tellus T46 hydraulic oilwhen oil temperatures consistentlyexceed 205°F / 96°C.
Genie specifications requireadditional equipment and specialinstallation instructions for theapproved optional fluids. Consultthe Genie Industries ServiceDepartment before use.
SPECIFICATIONS
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March 2005 Section 2 • Specifications
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 2 - 3
Function pump
Type: 2 section pressure balanced gear pump
Displacement 0.488 cu inper revolution (pump #1) 8 cc
Flow rate @ 3600 rpm 6.5 gpm(pump #1) 24.6 L/min
Displacement 0.488 cu inper revolution (pump #2) 8 cc
Flow rate @ 3600 rpm 6.5 gpm(pump #2) 24.6 L/min
Hydraulic tank 10 micron withreturn filter 25 psi / 1.7 bar bypass
Function manifold
System relief valve pressure 3500 psi(pump #1) 241.3 bar
System relief valve pressure 3500 psi(pump #2) 241.3 bar
Lift relief valve pressure, GS-2668 RT 3500 psi241.3 bar
Lift relief valve pressure, GS-3268 RT 2000 psi137.8 bar
Steer relief valve pressure 1500 psi103.4 bar
Steer flow regulator 2 gpm7.5 L/min
Outrigger manifold
Relief valve pressure 2000 psi137.8 bar
Generator manifold
Relief valve pressure 3000 psi206.8 bar
Flow rate 4.5 gpm17 L/min
Drive motors
Displacement 28.3 cu in464 cc
Manifold ComponentSpecifications
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
Description Specification
DO3 valve, 3 position 4 way 3.5 - 4.5Ω12V DC with diode (schematic items A and B)
Solenoid valve, 2 position 4 way 7 to 8Ω12V DC with diode (schematic item P)
Solenoid valve, 3 position 4 way 7 to 8Ω12V DC with diode (schematic item R)
Proportional valve, 4 to 6Ω12V DC (schematic item T)
Solenoid valve, 2 position 2 way 9 to 10Ω12V DC with diode (schematic items U, W, X and Y)
Solenoid valve, 2 position 3 way 5.5 to 6.5Ω12V DC (schematic item AB)
Solenoid valve, 2 position 2 way 8 to 10Ω12V DC with diode (schematic item AI)
Solenoid valve, 2 position 2 way 7 to 8Ω12V DC (schematic item BB)
Solenoid valve, 3 position 4 way 7 to 8Ω12V DC (schematic item BD)
Solenoid valve, 2 position 2 way 7.2 to 9.2Ω10V DC (schematic items CA, CB, CC and CD)
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
SPECIFICATIONS
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March 2005Section 2 • Specifications
REV B
2 - 4 GS-2668 RT • GS-3268 RT Part No. 52302
Kubota D905 Engine
Displacement 54.86 cu in0.90 liters
Number of cylinders 3
Bore and stroke 2.83 x 2.90 inches72 x 73.6 mm
Horsepower, gross intermittent 26 @ 3600 rpm19.3 kW
Firing order 1 - 2 - 3
Compression ratio 23:1
Compression pressure 412 to 469 psi28.4 to 32.3 bar
Low idle 1500 rpm300 hz
High idle 3000 rpm600 hz
Governor centrifugal mechanical
Valve clearance, cold 0.0057 to 0.0072 in0.145 to 0.185 mm
Engine coolant capacity 3.3 quarts3.1 liters
Lubrication system
Oil pressure 36 to 64 psi2.48 to 4.41 bar
Oil capacity (including filter) 5.4 quarts5.1 liters
Oil viscosity requirements 10W-30
Engine oil should have properties of API classificationCD or higher.
Injection system
Injection pump make Bosch MD
Injection timing 13° to 25° BTDC
Injection pump pressure 1991 psi137 bar
Fuel requirement 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 in13 mm
Brush length, minimum 0.3346 in8.5 mm
Alternator
Output 30A, 14V DC
Fan belt deflection 1/4 to 3/8 inch7 to 9 mm
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
SPECIFICATIONS
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March 2005 Section 2 • Specifications
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 2 - 5
Perkins 403C-11 Engine
Displacement 68.9 cu in1.13 liters
Number of cylinders 3
Bore and stroke 3.03 x 3.19 inches77 x 81 mm
Horsepower, gross intermittent 26.1 @ 3000 rpm19.5 kW
Firing order 1 - 2 - 3
Compression ratio 23:1
Compression pressure 425 psi29.3 bar
Pressure of the lowest cylinder must be within50 psi / 3.45 bar of the highest cylinder, thoughat no time less than 360 psi / 24.8 bar
Low idle 1500 rpm300 hz
High idle 3000 rpm600 hz
Governor all-speed mechanical
Valve clearance, cold 0.0078 in0.2 mm
Engine coolant capacity 3.28 quarts3.1 liters
Engine coolant should be clean soft water with 50% antifreeze concentration ethylene glycol to BS 6580:1992 orASTMD 3306-89 or AS 2108-1977
Lubrication system
Oil pressure 40 to 60 psi(hot @ 2000 rpm) 2.76 to 4.14 bar
Oil capacity (including filter) 4.3 quarts4.07 liters
Oil viscosity requirementsBelow 14°F / -10°C 0WFrom 14°F to 104°F / -10°C to 40°C 15W-40Above 104°F / 40°C 20W-50
Engine oil should have properties of API classificationCH4 or ACEA classification E5.
Injection system
Injection pump make Bosch
Injection timing 23° BTDC @ 3000 rpm
Injection pump pressure 2133 psi150 bar
Fuel requirement 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 inch5 mm
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
SPECIFICATIONS
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March 2005Section 2 • Specifications
REV B
2 - 6 GS-2668 RT • GS-3268 RT Part No. 52302
Kubota DF750 Engine
Displacement 45.21 cu in0.74 liters
Number of cylinders 3
Bore & stroke 2.68 x 2.68 inches68 x 68 mm
Horsepower, Gross intermittent 23.8 @ 3600 rpm17.7 kW @ 3600 rpm
Firing order 1 - 2 - 3
Low idle 1500 rpm300 hz
High idle 3300 rpm660 hz
Governor centrifugal ball mechanical
Compression ratio 9:1
Compression pressure 128 to 185 psi8.8 to 12.7 bar
Valve clearances, cold 0.0057 to 0.0072 inches0.145 to 0.085 mm
Lubrication system
Oil pressure 28 to 64 psi(operating temperature @ 3850 rpm) 1.9 to 4.4 bar
Oil capacity (including filter) 3.9 quarts3.7 liters
Oil viscosity requirements 10W-30
Engine oil should have properties of API classificationSH.
Fuel pump
Fuel pressure, static 2.84 psi0.19 bar
Fuel flow rate 0.125 gpm0.47 L/min
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
Starter motor
Brush length, new 0.669 in17 mm
Brush length wear limit 0.453 in11.5 mm
Brush spring tension 50 to 91 ounces13.7 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 1.6Ω@ 75°F / 24°C
Ignition coil secondary resistance 10.7 to 14.5 kΩ@ 75°F / 24°C
Spark plug wire resistance 10 to 22kΩ
Spark plug type NGK BCP4ES-11
Spark plug gap 0.039 to 0.043 inches1.0 to 1.1 mm
Engine coolant
Capacity 3.1 quarts2.9 liters
Alternator
Output 30A, 14V DC
Fan belt deflection 1/4 to 3/8 inch7 to 9 mm
SPECIFICATIONS
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March 2005 Section 2 • Specifications
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 2 - 7
Kubota DF752 Engine
Displacement 45.21 cu in0.74 liters
Number of cylinders 3
Bore & stroke 2.68 x 2.68 inches68 x 68 mm
Horsepower, Gross intermittent 24.8 @ 3600 rpm18.5 kW @ 3600 rpm
Firing order 1 - 2 - 3
Low idle 1500 rpm300 hz
High idle 3200 rpm640 hz
Governor centrifugal ball mechanical
Compression ratio 9.2:1
Compression pressure 128 to 185 psi8.8 to 12.7 bar
Valve clearances, cold 0.0057 to 0.0072 inches0.145 to 0.185 mm
Lubrication system
Oil pressure 28 to 64 psi(operating temperature @ 3850 rpm) 1.9 to 4.4 bar
Oil capacity (including filter) 3.4 quarts3.25 liters
Oil viscosity requirements 10W30
Engine oil should have properties of API classificationSH.
Fuel pump
Fuel pressure, static 2.84 psi0.19 bar
Fuel flow rate 0.125 gpm0.47 L/min
Continuous improvement of our products is aGenie policy. Product specifications aresubject to change without notice.
Starter motor
Brush length, new 0.669 in17 mm
Brush length wear limit 0.453 in11.5 mm
Brush spring tension 50 to 91 ounces13.7 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 1.6Ω@ 75°F / 24°C
Ignition coil secondary resistance 10.7 to 14.5 kΩ@ 75°F / 24°C
#1 Spark plug wire resistance 2.81 to 4.79kΩ
#2 Spark plug wire resistance 3.4 to 5.8kΩ
#3 Spark plug wire resistance 3.57 to 6.09kΩ
Spark plug type NGK BKR4E-11
Spark plug gap 0.039 to 0.043 inches1 to 1.1 mm
Engine coolant
Capacity 3.1 quarts2.9 liters
Alternator
Output 30A, 14V DC
Fan belt deflection 1/4 to 3/8 inch7 to 9 mm
SPECIFICATIONS
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March 2005Section 2 • Specifications
REV B
2 - 8 GS-2668 RT • GS-3268 RT Part No. 52302
Hydraulic Hose and FittingTorque SpecificationsYour machine is equipped with Parker Seal-Lok®
fittings and hose ends. Genie specifications requirethat fittings and hose ends be torqued tospecification when they are removed and installedor when new hoses or fittings are installed.
SAE O-ring Boss Port(tube fitting - installed into Aluminum)
SAE Dash size Torque
-4 11 ft-lbs / 14.9 Nm
-6 23 ft-lbs / 31.2 Nm
-8 40 ft-lbs / 54.2 Nm
-10 69 ft-lbs / 93.6 Nm
-12 93 ft-lbs / 126.1 Nm
-16 139 ft-lbs / 188.5 Nm
-20 172 ft-lbs / 233.2 Nm
-24 208 ft-lbs / 282 Nm
SAE O-ring Boss Port(tube fitting - installed into Steel)
SAE Dash size Torque
-4 16 ft-lbs / 21.7 Nm
-6 35 ft-lbs / 47.5 Nm
-8 60 ft-lbs / 81.3 Nm
-10 105 ft-lbs / 142.4 Nm
-12 140 ft-lbs / 190 Nm
-16 210 ft-lbs / 284.7 Nm
-20 260 ft-lbs / 352.5 Nm
-24 315 ft-lbs / 427.1 Nm
Seal-Lok® fittings
1 Replace the O-ring. The O-ring must bereplaced anytime the seal has been broken.The O-ring cannot be re-used if the fitting orhose end has been tightened beyond fingertight.
The O-rings used in the ParkerSeal Lok® fittings and hose endsare custom-size O-rings. They arenot standard SAE size O-rings.They are available in the O-ringfield service kit (Genie partnumber 49612).
2 Lubricate the O-ring before installation.
3 Be sure that the face seal O-ring is seated andretained properly.
4 Position the tube and nut squarely on the faceseal end of the fitting and tighten the nut fingertight.
5 Tighten the nut or fitting to the appropriatetorque per given size as shown in the table.
6 Operate all machine functions and inspect thehoses and fittings and related components toconfirm that there are no leaks.
Seal-Lok® Fittings(hose end)
SAE Dash size Torque
-4 18 ft-lbs / 24.4 Nm
-6 27 ft-lbs / 36.6 Nm
-8 40 ft-lbs / 54.2 Nm
-10 63 ft-lbs / 85.4 Nm
-12 90 ft-lbs / 122 Nm
-16 120 ft-lbs / 162.7 Nm
-20 140 ft-lbs / 190 Nm
-24 165 ft-lbs / 223.7 Nm
SPECIFICATIONS
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March 2005 Section 3 • Scheduled Maintenance Procedures
Part No. 52302 GS-2668 RT • GS-3268 RT 3 - 1
Scheduled Maintenance Procedures
Observe and Obey:
Maintenance inspections shall be completed bya person trained and qualified on themaintenance of this machine.
Scheduled maintenance inspections shall becompleted daily, quarterly, semi-annually,annually and every 2 years as specified on theMaintenance Inspection Report.
Failure to perform each procedureas presented and scheduled couldresult in death, serious injury orsubstantial damage.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Keep records on all inspections for three years.
Machines that have been out of service for aperiod longer than 3 months must complete thequarterly inspection.
Unless otherwise specified, perform eachmaintenance procedure with the machine in thefollowing configuration:
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the keyremoved
· The red Emergency Stop button in the offposition at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnectedfrom the machine
About This Section
This section contains detailed procedures for eachscheduled maintenance inspection.
Each procedure includes a description, safetywarnings and step-by-step instructions.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Without safety alert symbol—usedto indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Used to indicate operation ormaintenance information.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
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March 2005Section 3 • Scheduled Maintenance Procedures
3 - 2 GS-2668 RT • GS-3268 RT Part No. 52302
Maintenance Symbols Legend
The following symbols have beenused in this manual to helpcommunicate the intent of theinstructions. When one or more ofthe symbols appear at thebeginning of a maintenanceprocedure, it conveys the meaningbelow.
Indicates that tools will be required toperform this procedure.
Indicates that new parts will be requiredto perform this procedure.
Indicates that a cold engine will berequired to perform this procedure.
Indicates that a warm engine will berequired to perform this procedure.
Indicates that dealer service will berequired to perform this procedure.
Pre-delivery Preparation Report
The pre-delivery preparation report containschecklists for each type of scheduled inspection.
Make copies of the Pre-delivery Preparation reportto use for each inspection. Store completed formsas required.
Maintenance Schedule
There are five types of maintenance inspectionsthat must be performed according to a schedule—daily, quarterly, semi-annually, annually, andtwo year. The Scheduled Maintenance ProceduresSection and the Maintenance Inspection Reporthave been divided into five subsections—A, B, C,D, and E. Use the following chart to determinewhich group(s) of procedures are required toperform 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 containschecklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Reportto use for each inspection. Store completed formsfor three years.
SCHEDULED MAINTENANCE PROCEDURES
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March 2005 Section 3 • Scheduled Maintenance Procedures
Part No. 52302 GS-2668 RT • GS-3268 RT 3 - 3
Genie Industries USA18340 NE 76th StreetPO Box 97030Redmond, WA 98073-9730(425) 881-1800
Copyright © 2002 by Genie Industries. Genie® is a registered trademark of GenieIndustries. Rev B
Genie UKThe Maltings, Wharf Road
Grantham, LincolnshireNG31- 6BH England
(44) 1476-584333
Pre-Delivery Preparation Y N R
Pre-operation inspectioncompleted
Maintenance items completed
Function tests completed
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
Use the operator’s manual on your machine.
The Pre-delivery Preparation consists of completingthe Pre-operation Inspection, the Maintenance itemsand the Function Tests.
Use this form to record the results. Place a check inthe appropriate box after each part is completed.Follow the instructions in the operator’s manual.
If any inspection receives an N, remove the machinefrom service, repair and re-inspect it. After repair,place a check in the R box.
LegendY = yes, completedN = no, unable to completeR = repaired
Comments
Fundamentals
It is the responsibility of the dealer to perform thePre-delivery Preparation.
The Pre-delivery Preparation is performed prior toeach delivery. The inspection is designed to discover ifanything is apparently wrong with a machine before itis put into service.
A damaged or modified machine must never be used.If damage or any variation from factory deliveredcondition is discovered, the machine must be taggedand removed from service.
Repairs to the machine may only be made by aqualified service technician, according to themanufacturer's specifications.
Scheduled maintenance inspections shall beperformed by qualified service technicians, accordingto the manufacturer's specifications and therequirements listed in the responsibilities manual.
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March 2005Section 3 • Scheduled Maintenance Procedures
3 - 4 GS-2668 RT • GS-3268 RT Part No. 52302
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March 2005 Section 3 • Scheduled Maintenance Procedures
Part No. 52302 GS-2668 RT • GS-3268 RT 3 - 5
Maintenance Inspection Report
Checklist B - Rev B Y N R
B-1 Battery
B-2 Electrical wiring
B-3 Tires and wheels
B-4 Engine maintenance -Perkins 403C models
B-5 Key switch
B-6 Emergency Stop
B-7 Horn
B-8 Fuel select -Gasoline/LPG models
B-9 Drive brakes
B-10 Drive speed - stowed
B-11 Drive speed - raised
B-12 Tank venting systems
B-13 Hydraulic oil analysis
B-14 Flashing beacons(if equipped)
Perform every 400 hours:
B-15 Engine maintenance -Kubota D905 models
Checklist A - Rev B Y N R
A-1 Pre-operation inspect
A-2 Function tests
A-3 Engine maintenance
Perform every 40 hours:
A-4 Engine air filter
Perform after 40 hours:
A-5 Perform 30 day service
Perform after 50 hours:
A-6 Engine maintenance -Kubota D905 models
Perform every 50 hours:
A-7 Engine maintenance -Kubota models
Perform every 100 hours:
A-8 Engine maintenance -Kubota models
Perform every 200 hours:
A-9 Engine maintenance -Kubota models
A-10 Drain filter/separator -Diesel models
Perform every 1-2 months:
A-11 Engine maintenance -Kubota D905 models
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions· Make copies of this report to use for
each inspection.
· Select the appropriate checklist(s) forthe type of inspection to beperformed.
Daily or 8 hoursInspection: A
Quarterly or 250 hoursInspection: A+B
Semi-annually or 500 hoursInspection: A+B+C
Annually or 1000 hoursInspection: A+B+C+D
Two year or 2000 hoursInspection: A+B+C+D+E
· Place a check in the appropriate boxafter each inspection procedure iscompleted.
· Use the step-by-step procedures inthis section to learn how to performthese inspections.
· If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.
LegendY = yes, acceptableN = no, remove from serviceR = repaired
Comments
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March 2005Section 3 • Scheduled Maintenance Procedures
3 - 6 GS-2668 RT • GS-3268 RT Part No. 52302
MAINTENANCE INSPECTION REPORT
Model
Serial number
Date
Hour meter
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions· Make copies of this report to use for
each inspection.
· Select the appropriate checklist(s) forthe type of inspection to be performed.
Daily or 8 hoursInspection: A
Quarterly or 250 hoursInspection: A+B
Semi-annually or 500 hoursInspection: A+B+C
Annually or 1000 hoursInspection: A+B+C+D
Two year or 2000 hoursInspection: A+B+C+D+E
· Place a check in the appropriate boxafter each inspection procedure iscompleted.
· Use the step-by-step procedures inthis section to learn how to performthese inspections.
· If any inspection receives an “N”, tagand remove the machine from service,repair and re-inspect it. After repair,place a check in the “R” box.
LegendY = yes, acceptableN = no, remove from serviceR = repaired
Checklist C - Rev B Y N R
C-1 Platform overload(if equipped)
C-2 Fuel tank -Diesel models
C-3 Breather cap - modelswith optional oil
C-4 Engine maintenance -Diesel models
Perform every 800 hours:
C-5 Engine maintenance -Kubota D905, DF750
Checklist D - Rev B Y N R
D-1 Scissor arm wear pads
D-2 Platform overload(if equipped)
D-3 Hydraulic filter
D-4 Engine maintenance -Perkins 403C models
D-5 Engine maintenance -Kubota DF752 models
Perform annually:
D-6 Engine maintenance -Kubota models
Perform every 1500 hours:
D-7 Engine maintenance -Kubota D905
Checklist E - Rev B Y N R
E-1 Test or replacehydraulic oil
E-2 Engine maintenance -Perkins 403C models
E-3 Engine maintenance -Gasoline/LPG models
Perform every 3000 hours:
E-4 Engine maintenance -Perkins 403C models
Comments
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REV B
March 2005 Section 3 • Scheduled Maintenance Procedures
Part No. 52302 GS-2668 RT • GS-3268 RT 3 - 7
Checklist A Procedures
A-1Perform Pre-operation InspectionCompleting a Pre-operation Inspection is essentialto safe machine operation. The Pre-operationInspection is a visual inspection performed by theoperator prior to each work shift. The inspection isdesigned to discover if anything is apparentlywrong with a machine before the operator performsthe function tests. The Pre-operation Inspectionalso serves to determine if routine maintenanceprocedures are required.
Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.
A-2Perform Function TestsCompleting the function tests is essential to safemachine operation. Function tests are designed todiscover any malfunctions before the machine isput into service. A malfunctioning machine mustnever be used. If malfunctions are discovered, themachine must be tagged and removed fromservice.
Complete information to perform this procedure isavailable in the appropriate operator's manual.Refer to the Operator's Manual on your machine.
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REV B
March 2005Section 3 • Scheduled Maintenance Procedures
3 - 8 GS-2668 RT • GS-3268 RT Part No. 52302
A-3Perform Engine Maintenance
Engine specifications require thatthis procedure be performed every8 hours or daily, whichever comesfirst.
Required maintenance procedures and additionalengine information is available in theKubota DF750 Operator's Manual(Kubota part number EG261-8916-1) OR theKubota DF752 Operator's Manual(Kubota part number EG601-8916-1) OR theKubota D905 Operator's Manual(Kubota part number 16622-8916-5) OR thePerkins 403C-11 User's Handbook(Perkins part number 100816460).
Kubota DF750 Operator's ManualGenie part number 97359
Kubota DF752 Operator's ManualGenie part number 84250
Kubota D905 Operator's ManualGenie part number 84240
Perkins 403C-11 User's HandbookGenie part number 97360
A-4Inspect the Engine Air Filter
Genie specifications require thatthis procedure be performed every40 hours or weekly, whichevercomes first.
Maintaining the engine air filter in good condition isessential to good engine performance and servicelife. Failure to perform this procedure can lead topoor engine performance and component damage.
Perform this procedure with theengine off.
1 Kubota D905 models: Pull up on the enginetray locking pin, located under the radiator onthe engine pivot tray. Swing the engine pivottray out and away from the machine for access.
2 Kubota D905 models: Remove the wingnutsecuring the end cap to the air cleaner canister.Remove the end cap.
All other models: Disconnect the retainingclamps securing the end cap to the air cleanercanister. Remove the end cap.
3 Remove the air filter element.
4 Clean the inside of the air filter canister and thecanister gasket with a damp cloth.
5 Inspect for and remove any blockage or debrisfrom the intake air passages.
CHECKLIST A PROCEDURES
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REV B
March 2005 Section 3 • Scheduled Maintenance Procedures
Part No. 52302 GS-2668 RT • GS-3268 RT 3 - 9
6 Inspect the air filter element. If needed, blowfrom the inside out using low pressure drycompressed air, or carefully tap out dust.
7 Securely install the filter element into thecanister.
8 Install the gasket and baffle (if equipped), andend cap onto the air cleaner canister.
Be sure the dust discharge valveis facing down when installed.
9 Secure the end cap to the air cleaner cannisterwith the retaining clamps.
10 Kubota D905 models: Swing the engine pivottray back to its original position and make surethe engine tray locking pin locks into place.
CHECKLIST A PROCEDURES
A-5Perform 30 Day Service
The 30 day maintenance procedure is a one-timesequence of procedures to be performed after thefirst 30 days or 40 hours of usage. After thisinterval, refer to the maintenance checklists forcontinued scheduled maintenance.
1 Perform the following maintenance procedures:Kubota DF750 and DF752 models:
· A-10 Perform Engine Maintenance -Gasoline/LPG Models
· B-3 Inspect the Tires and Wheels(including lug nut torque)
· D-3 Replace the Hydraulic TankReturn Filter
Kubota D905 models:
· A-9 Perform Engine Maintenance -Kubota D905 Models
· B-3 Inspect the Tires and Wheels(including lug nut torque)
· D-3 Replace the Hydraulic TankReturn Filter
Perkins 403C-11 models:
· B-3 Inspect the Tires and Wheels(including lug nut torque)
· B-4 Perform Engine Maintenance -Perkins 403C-11 Models
· C-3 Perform Engine Maintenance -Diesel Models
· D-3 Replace the Hydraulic TankReturn Filter
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A-6Perform Engine Maintenance -Kubota D905 Models
Engine specifications require thatthis one time procedure beperformed after the first 50 hoursof operation.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5).
Kubota D905 Operator's ManualGenie part number 84240
A-7Perform Engine Maintenance -Kubota Models
Engine specifications require thatthis procedure be performed every50 hours or weekly, whichevercomes first.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5) OR theKubota DF750 Operator's Manual(Kubota part number EG261-8916-1) OR theKubota DF752 Operator's Manual(Kubota part number EG601-8916-1).
Kubota D905 Operator's ManualGenie part number 84240
Kubota DF750 Operator's ManualGenie part number 97359
Kubota DF752 Operator's ManualGenie part number 84250
CHECKLIST A PROCEDURES
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A-8Perform Engine Maintenance -Kubota Models
Engine specifications require thatthis procedure be performed every100 hours.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5) OR theKubota DF750 Operator's Manual(Kubota part number EG261-8916-1) OR theKubota DF752 Operator's Manual(Kubota part number EG601-8916-1).
Kubota D905 Operator's ManualGenie part number 84240
Kubota DF750 Operator's ManualGenie part number 97359
Kubota DF752 Operator's ManualGenie part number 84250
A-9Perform Engine Maintenance -Kubota Models
Engine specifications require thatthis procedure be performed every200 hours.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5) OR theKubota DF750 Operator's Manual(Kubota part number EG261-8916-1) OR theKubota DF752 Operator's Manual(Kubota part number EG601-8916-1).
Kubota D905 Operator's ManualGenie part number 84240
Kubota DF750 Operator's ManualGenie part number 97359
Kubota DF752 Operator's ManualGenie part number 84250
CHECKLIST A PROCEDURES
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A-10Drain the Fuel Filter/ WaterSeparator - Diesel Models
Genie specifications require thatthis procedure be performed every200 hours or monthly, whichevercomes first.
Proper maintenance of the fuel filter/waterseparator is essential for good engineperformance. Failure to perform this procedure canlead to poor engine performance and componentdamage.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Perform this procedure with theengine off.
1 Locate the fuel filter/water separator and loosenthe vent plug located on the fuel filter/waterseparator head.
2 Loosen the drain plug located at the bottom ofthe bowl. Allow the water to drain into a suitablecontainer until fuel starts to come out.Immediately tighten the drain plug.
a head boltb vent plugc separator headd filter bowle drain plug
3 Tighten the vent plug and clean up any spills orwet surfaces.
If the fuel bowl is completelydrained, you must prime, or bleed,the fuel filter/water separatorbefore starting the engine. Seestep 5.
4 Start the engine from the ground controls andcheck the fuel filter/water separator for leaks.
a
c
b
d
e
CHECKLIST A PROCEDURES
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CHECKLIST A PROCEDURES
Bleed the fuel system:
Before bleeding the system, fill thefuel tank.
5 Loosen the vent plug/screw located on the filterhead.
6 Operate the hand primer until fuel, free of air,flows from the vent plug/screw. Tighten the ventplug/screw on the filter head.
7 Loosen the vent screw, located on top of thefuel injection pump.
8 Operate the hand primer until fuel, free of air,flows from the vent plug/screw. Tighten the ventplug/screw on the injection pump.
9 Clean up any fuel that may have spilled.
10 Attempt to start the engine using the startermotor for a maximum of 15 seconds, resting thestarter for 30 seconds before trying again.
11 Inspect the fuel filter/water separator for leaks.
Explosion and fire hazard. If a fuelleak is discovered, keep anyadditional personnel from enteringthe area and do not operate themachine. Repair the leakimmediately.
Information to perform thisprocedure is also available in theKubota D905 Operator's Manual,(Kubota part number16622-8916-5) OR the Perkins403C-11 User's Handbook(Perkins part number 100816460).
Kubota D905 Operator's ManualGenie part number 84240
Perkins 403C-11 User's HandbookGenie part number 97360
A-11Perform Engine Maintenance -Kubota D905 Models
Engine specifications require thatthis procedure be performed everyone or two months.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5).
Kubota D905 Operator's ManualGenie part number 84240
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Checklist B Procedures
B-1Inspect the Battery
Proper battery condition is essential to goodengine performance and operational safety.Improper fluid levels or damaged cables andconnections can result in engine componentdamage and hazardous conditions.
Electrocution hazard. Contact withhot or live circuits could result indeath or serious injury. Remove allrings, watches and other jewelry.
Bodily injury hazard. Batteriescontain acid. Avoid spilling orcontacting battery acid. Neutralizebattery acid spills with baking sodaand water.
Perform this test after fullycharging the battery.
For a more accurate determinationof battery condition, fully chargethe battery and allow the battery torest 24 hours before performingthis procedure to allow the batterycells to equalize.
1 Put on protective clothing and eye wear.
2 Be sure that the battery cable connections arefree of corrosion.
Adding terminal protectors and acorrosion preventative sealant willhelp eliminate corrosion on thebattery terminals and cables.
3 Be sure that the battery hold downs and cableconnections are tight.
Models without maintenance-free or sealedbatteries:
4 Remove the battery vent caps and check thespecific gravity of each battery cell with ahydrometer.
Result: If any battery cell displays a specificgravity of less than 1.026, the battery must bereplaced.
5 Check the battery acid level of each battery cell.If needed, replenish with distilled water to thebottom of the battery fill tube. Do not overfill.
6 Install the battery vent caps.
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CHECKLIST B PROCEDURES
B-2Inspect the Electrical Wiring
Maintaining electrical wiring in good condition isessential to safe operation and good machineperformance. Failure to find and replace burnt,chafed, corroded or pinched wires could result inunsafe operating conditions and may causecomponent damage.
Electrocution hazard. Contactwith hot or live circuits mayresult in death or serious injury.Remove all rings, watches andother 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 greasein the following locations:
· Between the ECM and platform controls
· All wire harness connectors
· Level sensor
3 Turn the key switch to ground control and pullout the Emergency Stop button to the ON
position at both the ground and platformcontrols.
4 Start the engine and raise the platformapproximately 10 feet / 3 m from the ground.
5 Lift the safety arm, move to the center of thescissor arm and rotate down to a verticalposition.
6 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
7 Inspect the center chassis area and scissorarms 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 tothe stowed position.
10 Lower the platform to the stowed position andturn the machine off.
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B-3Inspect the Tires and Wheels(including castle nut and lug bolttorque)
Maintaining the tires and wheels in goodcondition is essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.
1 Check the tire tread and sidewalls for cuts,cracks, punctures and unusual wear.
2 Check each wheel for damage, bends andcracked welds.
3 Remove the castle nut lock plate or cotter pinand check each castle nut for proper torque.Refer to Section 2, Specifications.
Always replace the cotter pin witha new one when removing thecastle nut or checking the torqueof the castle nut.
4 Check each lug bolt for proper torque.
5 Install the castle nut lock plate using a new lockwasher OR install a new cotter pin and secure.
B-4Perform Engine Maintenance -Perkins 403C-11 Models
Engine specifications require thatthis procedure be performed every250 hours or six months,whichever comes first.
Required maintenance procedures and additionalengine information is available in thePerkins 403C-11 User's Handbook(Perkins part number 100816460).
Perkins 403C-11 User's HandbookGenie part number 97360
CHECKLIST B PROCEDURES
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B-5Test the Key SwitchProper key switch action and response is essentialto safe machine operation. The machine can beoperated from the ground or platform controls andthe activation of one or the other is accomplishedwith the key switch. Failure of the key switch toactivate the appropriate control panel could causea hazardous operating situation.
1 Pull out the red Emergency Stop button to theON position at both the ground and platformcontrols.
2 Turn the key switch to platform control.
3 Check the platform up/down function from theground controls.
Result: The machine functions should notoperate.
4 Turn the key switch to ground control.
5 Check the machine functions from the platformcontrols.
Result: The machine functions should notoperate.
6 Turn the key switch to the OFF position.
Result: The engine should stop and nofunctions should operate.
B-6Test the Emergency StopA properly functioning Emergency Stop is essentialfor safe machine operation. An improperlyoperating red Emergency Stop buttonwill fail to shut off power and stop all machinefunctions, resulting in a hazardous situation.
As a safety feature, selectingand operating the ground controlswill override the platform controls,except the platform redEmergency Stop button.
1 Start the engine from ground controls.
2 Push in the red Emergency Stop button to theoff position.
Result: The engine should shut off and nomachine functions should operate.
3 Start the engine from platform controls.
4 Push in the red Emergency Stop button to theoff position.
Result: The engine should shut off and nomachine functions should operate.
The red Emergency Stop button atthe ground controls should stop allmachine operation, even if the keyswitch is switched to platformcontrol.
CHECKLIST B PROCEDURES
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B-7Test the Automotive-style HornA functioning horn is essential to safe machineoperation. The horn is activated at the platformcontrols and sounds at the ground as a warning toground personnel. An improperly functioning hornwill prevent the operator from alerting groundpersonnel of hazards or unsafe conditions.
1 Turn the key switch to platform control andpull out the red Emergency Stop button to theON position at both the ground and platformcontrols.
2 Push down the horn button at the platformcontrols.
Result: The horn should sound.
If necessary, the horn can beadjusted to obtain the loudestvolume by turning the adjustmentscrew near the wire terminals onthe horn.
CHECKLIST B PROCEDURES
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CHECKLIST B PROCEDURES
B-8Test the Fuel Select Operation -Gasoline/LPG Models
The ability to select and switch betweengasoline and LPG fuels as needed is essential tosafe machine operation. A fuel selection can bemade whether the engine is running or not.Switching malfunctions and/or the failure of theengine to start and run properly in both fuelmodes and through all idle speeds can indicatefuel system problems that could develop into ahazardous situation.
Perform this test after checkingthe gasoline and LPG fuel levels,and warming the engine to normaloperating temperature.
Be sure that the valve on the LPGtank is in the OPEN position.
1 Move the fuel select toggle switch to thegasoline position at the ground controls.
2 Start the engine from the platform controls andallow the engine to run at low idle.
3 Press the high idle button at the platformcontrols to allow the engine to run at high idle.
Result: The high idle indicator light should be ON
and the engine should start promptly andoperate smoothly in low and high idle.
4 Press the high idle button again to return theengine to low idle.
Result: The high idle indicator light should turnOFF and the engine should return to low idle.
5 Press the engine stop button.
Result: The engine should stop.
6 Press the LPG operation button.
Result: The LPG indicator light should be ON.
7 Start the engine and allow it to run at low idle.
8 Press the high idle button to allow the engine torun at high idle.
Result: The high idle indicator light should be ON
and the engine should start promptly andoperate smoothly in low and high idle.
The engine may hesitatemomentarily and then continueto run on the selected fuel if thefuel source is switched whilethe engine is running.
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CHECKLIST B PROCEDURES
B-9Test the Drive Brakes
Proper brake action is essential to safe machineoperation. The drive brake function should operatesmoothly, free of hesitation, jerking and unusualnoise. Hydraulically-released individual wheelbrakes can appear to operate normally when theyare actually not fully operational.
Select a test area that is firm, leveland free of obstructions.
Be sure the extend deck is fullyretracted and the platform is in thestowed position.
1 Mark a test line on the ground for reference.
2 Start the engine from platform controls.
3 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the test line.
4 Slowly move the joystick in the directionindicated by the blue arrow on the control paneluntil the machine begins to move, then returnthe joystick to the center position.
Result: The machine should move in thedirection that the blue arrow points on thecontrol panel, then come to an abrupt stop.
5 Slowly move the joystick in the directionindicated by the yellow arrow on the controlpanel until the machine begins to move, thenreturn the joystick to the center position.
Result: The machine should move in thedirection that the yellow arrow points on thecontrol panel, then come to an abrupt stop.
6 Bring the machine to maximum drive speedbefore reaching the start line. Release thefunction enable switch on the joystick or releasethe joystick when your reference point on themachine crosses the test line.
7 Measure the distance between the test line andyour machine reference point.
The brakes must be able to holdthe machine on any slope it is ableto climb.
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March 2005 Section 3 • Scheduled Maintenance Procedures
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CHECKLIST B PROCEDURES
B-10Test the Drive Speed -Stowed Position
Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.
Select a test area that is firm, leveland free of obstructions.
Be sure the platform is fullyretracted and lowered to thestowed position.
1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.
2 Turn the key switch to platform controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.
3 Start the engine from the platform controls.
4 Lower the platform to the stowed position.
5 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.
Models before serial number GS6803-42382,and after serial number GS6803-42381 withsoftware revision B1 or lower:
6 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.
7 Continue at full speed and note the time whenthe machine reference point passes over thefinish line. Refer to Section 2, Specifications.
Models after serial number GS6803-42381 withsoftware revision C0 or higher:
6 Bring the machine to maximum forward drivespeed before reaching the start line. Begintiming when your reference point on themachine crosses the start line.
7 Continue at full speed and note the time whenthe machine reference point passes over thefinish line. Refer to Section 2, Specifications.
8 Bring the machine to maximum reverse drivespeed before reaching the start line. Begintiming when your reference point on themachine crosses the start line.
9 Continue at full speed and note the time whenthe machine reference point passes over thefinish line. Refer to Section 2, Specifications.
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CHECKLIST B PROCEDURES
B-11Test the Drive Speed -Raised Position
Proper drive function movement is essential tosafe machine operation. The drive function shouldrespond quickly and smoothly to operator control.Drive performance should also be free ofhesitation, jerking and unusual noise over theentire proportionally controlled speed range.
Select a test area that is firm, leveland free of obstructions.
1 Create start and finish lines by marking twolines on the ground 40 feet / 12.2 m apart.
2 Start the engine from the platform controls.
3 Raise the platform to approximately6 feet / 2 m.
4 Choose a point on the machine; i.e., contactpatch of a tire, as a visual reference for usewhen crossing the start and finish lines.
5 Bring the machine to maximum drive speedbefore reaching the start line. Begin timingwhen your reference point on the machinecrosses the start line.
6 Continue at maximum speed and note the timewhen your reference point on the machinecrosses the finish line. Refer to Section 2,Specifications.
If the raised drive speed does notmeet specifications, refer to theRepair procedure, 1-3, ControllerAdjustments.
GS-2668 RT before serial number 26563 andGS-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 driveposition.
Result: The drive function should not operate.
10 Lower the platform or retract the platformextension to drive.
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CHECKLIST B PROCEDURES
B-12Inspect the Fuel and HydraulicTank Cap Venting Systems
Genie requires that this procedurebe performed quarterly or every250 hours, whichever comes first.Perform this procedure more oftenif dusty conditions exist.
A free-breathing fuel tank cap is essential for goodengine performance and service life. A dirty orclogged fuel tank cap may cause the engine toperform poorly and continued use may causecomponent damage. Extremely dirty conditionsmay require that the cap be inspected more often.
Explosion and fire hazard. Enginefuels are combustible. Perform thisprocedure in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Perform this procedure with theengine off.
1 Remove the cap from the fuel tank.
2 Check for proper venting.
Result: Air passes through the fuel tank cap.
Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.
When checking for positive fueltank cap venting, air should passfreely through the cap.
3 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat step 2.
4 Install the fuel tank cap onto the fuel tank.
5 Remove the breather cap from the hydraulictank.
6 Check for proper venting.
Result: Air passes through the breather cap.
Result: If air does not pass through the cap,clean or replace the cap. Proceed to step 3.
When checking for positive fueltank cap venting, air should passfreely through the cap.
7 Using a mild solvent, carefully wash the capventing system. Dry using low pressurecompressed air. Repeat step 2.
8 Install the breather cap onto the fuel tank.
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CHECKLIST B PROCEDURES
B-13Perform Hydraulic Oil Analysis
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and a clogged suction strainermay cause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.
Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test. See E-1,Test or Replace the Hydraulic Oil.
B-14Test the Flashing Beacons(if equipped)Flashing beacons are used to alert operators andground personnel of machine proximity andmotion. The flashing beacons are located on bothsides of the machine.
1 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.
Result: The beacons should flash.
2 Turn the key switch to platform controls.
Result: The beacons should flash.
B-15Perform Engine Maintenance -Kubota D905 Models
Engine specifications require thatthis procedure be performed every400 hours.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5).
Kubota D905 Operator's ManualGenie part number 84240
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Checklist C Procedures
C-1Test thePlatform Overload System(if equipped)
Genie specifications require thatthis procedure be performed every500 hours or six months,whichever comes first OR whenthe machine fails to lift themaximum rated load.
Testing the platform overload system regularly isessential to safe machine operation. Continueduse of an improperly operating platform overloadsystem could result in the system not sensing anoverloaded platform condition. Machine stabilitycould be compromised resulting in the machinetipping over.
Perform this procedure with themachine on a firm, level surfacethat is free of obstructions.
1 Disconnect the platform controls from themachine at the platform.
2 Open the ground control panel and locate theElectronic Control Module (ECM).
3 Tag and disconnect the platform controls wireharness from the ECM wire harness.
4 Securely connect the platform controls to theECM wire harness.
5 Locate the terminal strip behind the groundcontrol panel.
6 Tag and disconnect the black wire of themaximum height limit switch wire harness fromthe A10 terminal of the terminal strip.
7 Tag and disconnect the white wire of themaximum height limit switch wire harness fromthe B9 terminal of the terminal strip.
8 Securely connect a jumper wire from terminalA10 of the terminal strip to terminal B9 of theterminal strip.
9 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.
10 Fully raise the platform. Release the joystick.
Result: The engine should stop and an alarmshould sound and fault code 99 PLATFORM
OVERLOAD should be present in the ECMdiagnostic display window at the groundcontrols.
11 Activate the auxiliary lowering function andlower the platform approximately 4.5 m.
12 Turn the key switch to the off position.
13 Disconnect the jumper wire from terminal A10of the terminal strip to terminal B9 of theterminal strip.
14 Securely connect the black wire of themaximum height limit switch wire harness toterminal A10 of the terminal strip.
15 Securely connect the white wire of themaximum height limit switch wire harness toterminal B9 of the terminal strip.
16 Turn the key switch to platform control.
17 Fully raise the platform. Release the joystick.
Result: The platform should stop raising atmaximum height. The engine should continueto run and an alarm should not sound.
18 Lower the platform to the stowed position.
19 Disconnect the platform controls from the ECMwire harness.
20 Securely connect the platform controls wireharness to the ECM wire harness.
21 Securely connect the platform controls to theplatform controls wire harness at the platform.
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CHECKLIST C PROCEDURES
C-2Clean the Fuel Tank -Diesel Models
Removing sediment from the fuel tank is essentialto good engine performance and service life. Adirty fuel tank may cause the fuel filter to clogprematurely resulting in poor engine performanceand possible component damage.
Explosion and fire hazard. Enginefuels are combustible. Clean thefuel tank in an open, well-ventilated area away from heater,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Immediately clean up any fuel thatmay have spilled during thisprocedure.
Perform this procedure with theengine off.
1 Models with fuel shutoff valve: Turn themanual fuel shutoff valve, located above thefuel filter, to the closed position.
2 Tag, disconnect and plug the fuel supply andreturn hoses at the filter head and the fuelreturn pipe at the injectors. Clean up any fuelthat may have spilled.
3 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Refer toSection 2, Specifications, for tank capacity.
Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.
Be sure to only use a handoperated pump suitable for usewith gasoline and/or diesel fuel.
4 Remove the tank retaining fasteners from thebottom of the fuel tank and remove the tankfrom the machine.
Component damage hazard. Thefuel tank is plastic and maybecome damaged if allowed to fall.
5 Tag and remove the hoses and fittings from thetop of the tank.
6 Rinse out the inside of the tank using a mildsolvent.
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 routethe hoses through the bulkhead. Install andtighten the tank retaining fasteners tospecification.
Torque specifications
Fuel tank retaining fasteners, dry 175 in-lbs19.8 Nm
Fuel tank retaining fasteners, lubricated 131 in-lbs14.8 Nm
9 Install the fuel supply and return hoses onto thefilter head and the fuel return pipe at theinjectors. Tighten the clamps.
10 Models with fuel shutoff valve: Turn themanual fuel shutoff valve, located above thefuel filter, to the open position.
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CHECKLIST C PROCEDURES
C-3Replace theHydraulic Tank Breather Cap -Models with Optional Hydraulic Oil
The hydraulic tank is a vented-type tank. Thebreather cap has an internal air filter that canbecome clogged or, over time, can deteriorate. Ifthe breather cap is faulty or improperly installed,impurities can enter the hydraulic system whichmay cause component damage. Extremely dirtyconditions may require that the cap be inspectedmore often.
1 Remove and discard the hydraulic tank breathercap.
2 Install and new cap onto the tank.
C-4Perform Engine Maintenance -Diesel Models
Engine specifications require thatthis procedure be performed every500 hours.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5) OR thePerkins 403C-11 User's Handbook(Perkins part number 100816460).
Kubota D905 Operator's ManualGenie part number 84240
Perkins 403C-11 User's HandbookGenie part number 97360
C-5Perform Engine Maintenance -Kubota D905 and DF750 Models
Engine specifications require thatthis procedure be performed every800 hours.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5) OR theKubota DF750 Operator's Manual(Kubota part number EG261-8916-1).
Kubota D905 Operator's ManualGenie part number 84240
Kubota DF750 Operator's ManualGenie part number 97359
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Checklist D Procedures
D-1Check the Scissor Arm WearPads
Maintaining the scissor arm wear pads in goodcondition is essential to safe machine operation.Continued use of worn out wear pads may result incomponent damage and unsafe operatingconditions.
Perform this procedure on a firm,level surface with the platform inthe stowed position.
1 Measure the thickness of each chassis wearpad at the steer end of the machine.
Result: The measurement is 5/16 inch / 8 mm ormore. Proceed to step 2.
Result: The measurement is less than5/16 inch / 8 mm. Replace both wear pads.
2 Measure the thickness of each chassis wearpad at the non-steer end of the machine.
Result: The measurement is 5/16 inch / 8 mm ormore. Proceed to step 3.
Result: The measurement is less than5/16 inch / 8 mm. Replace both wear pads.
3 Measure the thickness of each platform scissorarm wear pad at the steer end of the machine.
Result: The measurement is 5/16 inch / 8 mm ormore. Proceed to step 4.
Result: The measurement is less than5/16 inch / 8 mm. Replace both wear pads.
4 Measure the thickness of each platform scissorarm wear pad at the non-steer end of themachine.
Result: The measurement is 5/16 inch / 8 mm ormore.
Result: The measurement is less than5/16 inch / 8 mm. Replace both wear pads.
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CHECKLIST D PROCEDURES
D-2Calibrate thePlatform Overload System(if equipped)
Genie specifications require thatthis procedure be performed every1000 hours or annually, whichevercomes first.
On machines with platform overload systems,proper calibration is essential to safe machineoperation. An improperly calibrated platformoverload system could result in the system failingto sense an overloaded platform. The stability ofthe machine is compromised and it could tip over.
Be sure the hydraulic oil level isbetween the full and add marks onthe oil level indicator.
Perform this procedure with themachine on a firm, level surfacethat is free of obstructions.
1 Models with outriggers: Deploy the outriggersand level the machine.
2 Apply a thin layer of dry film lubricant to thearea of the chassis where the scissor arm wearpads make contact.
3 Disconnect the platform controls from themachine at the platform.
4 Open the side cover at the ground controls sideof the machine and locate the ElectronicControl Module (ECM) wire harness to platformcontrols wire harness connection above thehydraulic tank.
5 Tag and disconnect the platform controls wireharness from the ECM wire harness.
6 Securely connect the platform controls to theECM wire harness.
7 Using a suitable lifting device, place a testweight, corresponding to the maximum load asindicated on the capacity indicator decal, in thecenter of the platform floor. Secure the weightto the platform. Refer to the chart below.
GS-2668 975 kg
GS-3268 919 kg
8 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols. Start the engine.
9 Raise the platform to approximately 4 m.
10 Rotate the safety arm away from the machineand let it hang down.
11 Remove the cover from the pressure switch.
The pressure switch is located onthe lift cylinder.
12 Slowly turn the nut of the platform overloadpressure switch one-quarter turn into thehydraulic line.
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CHECKLIST D PROCEDURES
13 Push in the red Emergency Stop button to theoff position at the ground controls.
14 Pull out the red Emergency Stop button to theon position at the ground controls. Wait 3seconds and start the engine.
Result: The alarm doesn't sound and the enginewill start and run. Proceed to step 15.
Result: The engine will not start and an alarm issounding. Repeat this procedure beginning withstep 12.
The red Emergency Stop buttonmust be cycled after each quarterturn of the nut to allow the platformoverload system to reset.
Wait a minimum of 3 secondsbetween each quarter turn of thenut to allow the platform overloadsystem to reset.
15 Raise the platform until the position indicatorcorresponds to the maximum load position ofthe capacity indicator decal.
Tip-over hazard. Raising theplatform with maximum loadabove the maximum load position,as shown on the capacity indicatordecal on the side of the platform,could result in the machine tippingover, resulting in death or seriousinjury. Do not raise the platformabove the maximum load positionof the capacity indicator decal.
To perform this step, the lift reliefvalve will need to be adjusted.
Before raising the platform,applying a piece of tape onto theunderside of the platform, at apoint which corresponds to themaximum load position of thecapacity indicator decal, may helpcomplete this part of theprocedure.
Result: The engine continues to run. Proceed tostep 16.
Result: The engine has stopped and an alarm issounding. Proceed to step 17.
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CHECKLIST D PROCEDURES
Set the pressure switch:
16 Using a wrench, turn the nut of the platformoverload pressure switch out of the hydraulicline until the overload alarm sounds and theengine stops running.
Turning the nut out of thehydraulic line will activate thealarm; turning the nut into thehydraulic line will deactivate thealarm.
17 Slowly turn the nut of the platform overloadpressure switch one-quarter turn into thehydraulic line.
18 Push in the red Emergency Stop button to theoff position at the ground controls.
19 Pull out the red Emergency Stop button to theon position at the ground controls. Wait 3seconds and start the engine.
Result: The alarm doesn't sound and the enginewill start and run. Proceed to step 20.
Result: The engine will not start and an alarm issounding. Repeat this procedure beginning withstep 17.
The red Emergency Stop buttonmust be cycled after each quarterturn of the nut to allow the platformoverload system to reset.
Wait a minimum of 3 secondsbetween each quarter turn of thenut to allow the platform overloadsystem to reset.
20 Return the safety arm to the stowed position.Lower the platform to the stowed position.
After returning the safety arm tothe stowed position, use theauxiliary down function to lowerthe platform.
Set the maximum height limit switch:
21 Using a suitable lifting device, place a testweight in the center of the platform floor.Secure the weight to the platform. Refer to thechart below.
GS-2668 RT 567 kg
GS-3268 RT 454 kg
22 Raise the platform to approximately 4 m.
23 Rotate the safety arm away from the machineand let it hang down.
24 Remove the maximum height limit switchfasteners. Remove the maximum height limitswitch and set it to the side so that the limitswitch will not be activated.
25 Raise the platform until it is approximately65 cm less than full height.
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CHECKLIST D PROCEDURES
26 Raise the platform in 5 cm increments until theoverload alarm sounds and the engine stopsrunning. Proceed to step 27.
Result: The alarm does not sound and theengine continues to run when the platformreaches full height. Repeat this procedurebeginning with step 7.
27 Install and adjust the maximum height limitswitch until it activates just before the pointreached in step 26. Securely tighten thefasteners. Do not over tighten.
28 Use the auxiliary down function to lower theplatform approximately 15 cm.
29 Start the engine and fully raise the platform.
Result: The engine continues to run. Proceed tostep 30.
Result: An alarm sounds and the engine stopsrunning. Repeat this procedure beginning withstep 24.
30 Lower the platform to approximately 4 m.
31 Return the safety arm to the stowed position.
Disable the descent delay function:
32 Push in the red Emergency Stop button to theoff position at the ground controls.
33 Turn the key switch to ground control.
Limit switch legend
a maximum height limit switchb down limit switchc load sense delay limit switch
ba c
GS-2668
GS-3268
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March 2005 Section 3 • Scheduled Maintenance Procedures
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CHECKLIST D PROCEDURES
b
c
d
a
34 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window.
39 Pull out the red Emergency Stop button to theon position at the ground controls.
For more information onprogramming, refer to Section 4,Repair.
Calibrate the load sense delay limit switch:
40 Turn the key switch to platform control. Start theengine.
41 Lower the platform until the load sense delaylimit switch activates and the platform stopslowering. Release the joystick.
Result: The alarm does not sound and theengine continues to run. Proceed to step 49.
Result: The alarm sounds and the enginesstops running. The load sense delay limit switchneeds to be calibrated. Proceed to step 42.
42 Raise the platform to approximately 4 m.
43 Rotate the safety arm away from the machineand let it hang down.
44 Loosen the fasteners securing the load sensedelay limit switch just enough to allowmovement of the limit switch.
45 Move the roller head of the load sense delaylimit switch 1 mm upwards. Tighten thefasteners. 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.
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
35 Use the yellow platform down arrow to scroll toSELECT OPTIONS.
Result: SELECT OPTIONS is showing in thediagnostic display window. The ECM is now inprogramming mode.
36 Press the lift function enable button.
Result: DESCENT DELAY ON is showing in thediagnostic display window.
37 Press the lift function enable button todeactivate the descent delay option.
Result: DESCENT DELAY OFF is showing in thediagnostic display window.
38 Push in the red Emergency Stop button to theoff position at the ground controls.
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Enable the descent delay function:
49 Push in the red Emergency Stop button to theoff position at the ground controls.
50 Turn the key switch to ground control.
51 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window.
52 Use the yellow platform down arrow to scroll toselect options.
Result: SELECT OPTIONS is showing in thediagnostic display window. The ECM is now inprogramming mode.
53 Press the lift function enable button.
Result: DESCENT DELAY OFF is showing in thediagnostic display window.
54 Press the lift function enable button to activatethe descent delay option.
Result: DESCENT DELAY ON is showing in thediagnostic display window.
55 Push in the red Emergency Stop button to theoff position at the ground controls.
56 Pull out the red Emergency Stop button to theon position at the ground controls.
Calibrate the down limit switch:
57 Turn the key switch to platform control. Start theengine.
58 Raise the platform approximately 1 m.
59 Lower the platform until the down limit switchactivates and the platform stops lowering.Quickly release the controls and thenimmediately attempt to lower the platform tothe 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 willimmediately begin to lower again. The downlimit switch needs to be calibrated. Proceed tostep 60.
60 Raise the platform to approximately 4 m.
61 Rotate the safety arm away from the machineand let it hang down.
62 Loosen the fasteners securing the down limitswitch just enough to allow movement of thelimit switch.
63 Move the roller head of the down limit switch1 mm upwards. Tighten the fasteners. Do notover 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.
CHECKLIST D PROCEDURES
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CHECKLIST D PROCEDURES
67 Lower the platform to the stowed position andremove the weight from the platform.
Result: The platform lowers to the stowedposition. Proceed to step 72.
Result: The platform stops lowering. The downlimit switch needs to be calibrated. Proceed tostep 68.
68 Raise the platform to approximately 4 m.
69 Rotate the safety arm away from the machineand let it hang down..
70 Loosen the fasteners securing the down limitswitch just enough to allow movement of thelimit switch.
71 Move the roller head of the down limit switch1 mm downwards. Tighten the fasteners. Donot over tighten.
72 Raise the platform to approximately 4 m.
73 Rotate the safety arm away from the machineand let it hang down.
74 Install the cover onto the platform overloadpressure switch box and securely tighten thecover retaining fasteners. Do not over tighten.
75 Apply Sentry Seal to one of the cover retainingfasteners where it contacts the platformoverload 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.
CONDITION POSSIBLE CAUSE SOLUTIONCANNOT LIFT RATED LOAD RELIEF VALVE SET TOO LOW INCREASE RELIEF VALVE PRESSURE
AT MAXIMUM HEIGHT WITH RATED LOAD IN PLATFORM, THE PRESSURE SWITCH ALARM CONTINUES TO SOUND
SYSTEM NEEDS TO BE RESETTURN OFF RED EMERGENCY STOP BUTTON, WAIT THREE SECONDS AND TURN BACK ON
MAXIMUM HEIGHT LIMIT SWITCH OUT OF ADJUSTMENT -OR- FAULTY
LOWER THE UP LIMIT SWITCH SLIGHTLY -OR- REPLACE CONTACTS
TOO MUCH WEIGHT IN PLATFORM PUT CORRECT RATED LOAD IN PLATFORM
PRESSURE SWITCH OUT OF ADJUSTMENTTURN THE PRESSURE SWITCH NUT 1/4 TURN INTO THE HYDRAULIC LINE
BATTERIES ARE NOT FULLY CHARGED CHARGE BATTERIESOVERLOAD SYSTEM NOT ADJUSTED PROPERLY
REPEAT CALIBRATION PROCEDURE
SLIDER CHANNEL NOT LUBRICATED LUBRICATE SLIDER CHANNELS
AT DOWN LIMIT WITH RATED LOAD IN PLATFORM, THE PRESSURE SWITCH ALARM CONTINUES TO SOUND
SYSTEM NEEDS TO BE RESETTURN OFF RED EMERGENCY STOP BUTTON, WAIT THREE SECONDS AND TURN BACK ON
DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCHTOO MUCH WEIGHT IN PLATFORM PUT CORRECT RATED LOAD IN PLATFORM
OVERLOAD SYSTEM NOT ADJUSTED PROPERLY
TURN THE PRESSURE SWITCH NUT 1/4 TURN INTO THE HYDRAULIC LINE -OR- REPEAT CALIBRATION PROCEDURE
TROUBLESHOOTING THE PLATFORM OVERLOAD SYSTEM
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CHECKLIST D PROCEDURES
D-3Replace the Hydraulic TankReturn Filter
Replacement of the hydraulic tank return filter isessential for good machine performance andservice life. A dirty or clogged filter may cause themachine to perform poorly and continued use maycause component damage. Extremely dirtyconditions may require that the filter be replacedmore often.
Bodily injury hazard. Beware ofhot oil. Contact with hot oil maycause severe burns.
The hydraulic filter is mounted onthe hydraulic tank.
1 Remove the filter with an oil filter wrench. Cleanthe area where the hydraulic oil filter meets thefilter head.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
2 Apply a thin layer of fresh oil to the new oil filtergasket.
3 Install the new filter and tighten it securely byhand.
4 Use a permanent ink marker to write the dateand number of hours from the hour meter onthe filter.
5 Clean up any oil that may have spilled duringthe replacement procedure.
6 Turn the key switch to ground controls and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols. Start the engine.
7 Raise the platform approximately 3 feet / 1 m.
8 Inspect the filter and related components tobe sure that there are no leaks.
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CHECKLIST D PROCEDURES
D-4Perform Engine Maintenance -Perkins 403C-11 Models
Engine specifications require thatthis procedure be performed every1000 hours.
Required maintenance procedures and additionalengine information is available in thePerkins 403C-11 User's Handbook(Perkins part number 100816460).
Perkins 403C-11 User's HandbookGenie part number 97360
D-5Perform Engine Maintenance -Kubota DF752 Models
Engine specifications require thatthis procedure be performed every1000 hours.
Required maintenance procedures and additionalengine information is available in theKubota DF752 Operator's Manual(Kubota part number EG601-8916-1).
Kubota DF752 Operator's ManualGenie part number 84250
D-6Perform Engine Maintenance -Kubota Models
Engine specifications require thatthis procedure be performedannually.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5) OR theKubota DF750 Operator's Manual(Kubota part number EG261-8916-1) OR theKubota DF752 Operator's Manual(Kubota part number EG601-8916-1).
Kubota D905 Operator's ManualGenie part number 84240
Kubota DF750 Operator's ManualGenie part number 97359
Kubota DF752 Operator's ManualGenie part number 84250
D-7Perform Engine Maintenance -Kubota D905 Models
Engine specifications require thatthis procedure be performed every1500 hours.
Required maintenance procedures and additionalengine information is available in theKubota D905 Operator's Manual(Kubota part number 16622-8916-5).
Kubota D905 Operator's ManualGenie part number 84240
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Checklist E Procedures
E-1Test or Replace the Hydraulic Oil
Replacement or testing of the hydraulic oil isessential for good machine performance andservice life. Dirty oil and suction strainers maycause the machine to perform poorly andcontinued use may cause component damage.Extremely dirty conditions may require oil changesto be performed more often.
Before replacing the hydraulic oil,the oil may be tested by an oildistributor for specific levels ofcontamination to verify thatchanging the oil is necessary. Ifthe hydraulic oil is not replacedat the two year inspection, testthe oil quarterly. Replace the oilwhen it fails the test.
1 Raise the platform approximately 10 feet / 3 m.
2 Lift the safety arm, move to the center of thescissor arm and rotate down to a verticalposition.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
4 Push in the red Emergency Stop button to theoff position.
5 Locate the hose cover plate in the center of thedrive chassis. Remove the hose cover platemounting fasteners and remove the cover.
6 If equipped, close the two hydraulic shutoffvalves located at the hydraulic tank.
Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
7 Place a drain pan or other suitable containerunder the hydraulic tank. Refer to Section 2,Specifications.
8 Remove the drain plug from the hydraulic tankand completely drain the tank.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
9 Tag and disconnect the two suction hoses fromthe hydraulic tank.
10 Disconnect and plug the hydraulic hose at thereturn filter. Cap the fitting on the filter.
11 Remove the tank strap retaining fasteners andremove the tank strap from the machine.
12 Remove the hydraulic tank from the machine.
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CHECKLIST E PROCEDURES
13 Remove the suction strainers and clean themusing a mild solvent.
14 Clean the inside of the hydraulic tank using amild solvent.
15 Install the suction strainers using thread sealeron the threads.
16 Install the drain plug using thread sealer on thethreads.
17 Install the hydraulic tank, tank strap and tankstrap 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 iswithin the top 2 inches / 5 cm of the sightgauge. Do not overfill.
21 Clean up any oil that may have spilled. Properlydiscard the oil.
22 If equipped, open the two hydraulic shutoffvalves located at the hydraulic tank.
23 Operate all machine functions through a fullcycle and check for leaks.
24 Install the hose cover plate and install the hosecover plate mounting fasteners.
E-2Perform Engine Maintenance -Perkins 403C-11 Models
Engine specifications require thatthis procedure be performed every2000 hours.
Required maintenance procedures and additionalengine information is available in thePerkins 403C-11 User's Handbook(Perkins part number 100816460).
Perkins 403C-11 User's HandbookGenie part number 97360
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REV B
March 2005Section 3 • Scheduled Maintenance Procedures
3 - 40 GS-2668 RT • GS-3268 RT Part No. 52302
E-3Perform Engine Maintenance -Gasoline/LPG Models
Engine specifications require thatthis procedure be performed everytwo years.
Required maintenance procedures and additionalengine information is available in the KubotaDF750 Operator's Manual (Kubota part numberEG261-8916-1) OR the Kubota DF752 Operator'sManual (Kubota part number EG601-8916-1).
Kubota DF750 Operator's ManualGenie part number 97359
Kubota DF752 Operator's ManualGenie part number 84250
E-4Perform Engine Maintenance -Perkins 403C-11 Models
Engine specifications require thatthis procedure be performed every3000 hours.
Required maintenance procedures and additionalengine information is available in thePerkins 403C-11 User's Handbook(Perkins part number 100816460).
Perkins 403C-11 User's HandbookGenie part number 97360
CHECKLIST E PROCEDURES
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Section 4 • Repair ProceduresMarch 2005
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 1
Repair Procedures
About This Section
Most of the procedures in this section should onlybe performed by a trained service professionalin a suitably equipped workshop. Select theappropriate repair procedure after troubleshootingthe problem. Perform disassembly procedures tothe point where repairs can be completed. Tore-assemble, perform the disassembly steps inreverse order.
Symbols Legend
Safety alert symbol—used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.
Used to indicate the presence ofan imminently hazardous situationwhich, if not avoided, will result indeath or serious injury.
Used to indicate the presence of apotentially hazardous situationwhich, if not avoided, could resultin death or serious injury.
With safety alert symbol—used toindicate the presence of apotentially hazardous situationwhich, if not avoided, may causeminor or moderate injury.
Without safety alert symbol—usedto indicate the presence of apotentially hazardous situationwhich, if not avoided, may result inproperty damage.
Used to indicate operation ormaintenance information.
Indicates that a specific result is expected afterperforming a series of steps.
Indicates that an incorrect result has occurredafter performing a series of steps.
Observe and Obey:Repair procedures shall be completed by aperson trained and qualified on the repair of thismachine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Repairs Start:Read, understand and obey the safety rulesand operating instructions in the appropriateoperator’s manual on your machine.
Be sure that all necessary tools and parts areavailable and ready for use.
Read each procedure completely and adhereto the instructions. Attempting shortcuts mayproduce hazardous conditions.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the keyremoved
· The red Emergency Stop button in the offposition at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnectedfrom the machine
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Section 4 • Repair Procedures March 2005
REV B
4 - 2 GS-2668 RT • GS-3268 RT Part No. 52302
Platform Controls
The platform controls, used to activate machinefunctions from the platform or while standing on theground, contain a printed circuit board, joystick,decal membrane pad, buttons and/or toggleswitches, and LEDs. All of these components arereplaceable though only the potentiometer-equipped joystick, used before serial numberGS6803-42382, is serviceable.
On models before serial number GS6803-42382,the platform controls are also used to tune theperformance of the machine.
The function speed parameters in the ElectronicControl Module are easily adjusted by moving thejoystick, pressing a button or activating a toggleswitch in a specific order when the ECM is in theprogramming mode (PS showing in the diagnosticdisplay window).
For further information or assistance, consult theGenie Industries Service Department.
Platform controls before serial number GS6803-42382
a alarm H1b function enable/high speed select button for
platform up/down function BN12c function enable/low speed select button for
platform up/down function BN13d platform up/down toggle switch TS20 OR
platform up/down and outrigger up/downtoggle switch TS21
e circuit board U3f DIP switch SW25g joystick controller JC1h potentiometeri red Emergency Stop button P2
Platform controls after serial number GS6803-42381
a
b
c
d
e
f
i
g
h
1
2
NC
a
i
g
e
d
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 3
1-1Circuit Boards
How to Remove the PlatformControls Circuit Board1 Push in the red Emergency Stop button to the
off position at both the ground and platformcontrols.
2 Loosen the platform control box lid retainingfasteners. Open the control box and secure thecontrol box lid in a level position.
3 Visually locate the circuit board mounted to theinside of the platform control box lid.
4 Tag and disconnect the wire connections fromthe red Emergency Stop button.
5 Tag and disconnect the wire harnessconnectors from the platform controls circuitboard.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
Component damage hazard.Electrostatic discharge (ESD) candamage printed circuit boardcomponents. Maintain firm contactwith a metal part of the machinethat is grounded at all times whenhandling printed circuit boards ORuse a grounded wrist strap.
6 Remove the platform controls circuit boardretaining fasteners.
7 Remove the platform controls circuit board fromthe platform control box lid.
PLATFORM CONTROLS
1-2Joystick Controller
Maintaining the joystick at the proper setting isessential to safe machine operation. The joystickshould operate smoothly over its entire range ofmotion.
Machines after serial number GS6803-42381 areequipped with Hall-effect joysticks, which do notrequire calibration.
How to Calibrate the Joystick(before serial number GS6803-42382)
If the joystick is out of calibration,fault code 30 will be present on thediagnostic display and the errorindicator light will be illuminated atthe platform controls.
1 Turn the key switch to platform control and pullout the red Emergency Stop button to the ON
position at both the ground and platformcontrols.
2 Remove the platform control box lid retainingfasteners. Open the control box lid.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
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Section 4 • Repair Procedures March 2005
REV B
4 - 4 GS-2668 RT • GS-3268 RT Part No. 52302
PLATFORM CONTROLS
3 Locate the potentiometer on the base of thejoystick.
a joystick controller JC1b potentiometer shaft slotc potentiometer shaft set screwd platform controls circuit board U3e potentiometerf brown wireg purple wire
4 Using a volt meter set to read DC voltage, placethe voltmeter negative lead on the purple wire.Place the volt meter positive lead on the brownwire.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
5 Loosen the set screw on the potentiometershaft just enough to allow the shaft to rotate.
6 With the joystick in the center or neutralposition, adjust the potentiometer shaft until2.05V DC is displayed on the voltmeter. Tightenthe set screw.
7 Move the joystick full stroke in both directionsseveral times. Return the joystick to the centerposition.
Result: The voltmeter should read 2.05V DC.
Result: If the voltmeter does not read2.05V DC, repeat steps 5 through 8.
8 Turn the key switch to the off position.
9 Wait a few seconds and then turn the keyswitch to platform control.
Result: The error indicator light on the top of theplatform control box should not be illuminatedand code 30 should not be present on thediagnostic display.
Result: If the error indicator light is illuminatedor if code 30 is present on the diagnosticdisplay, repeat this procedure beginning withstep 5.
10 Turn the key switch to the off position.
11 Close the lid and install the fasteners.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 5
How to Determine the RevisionLevel
Models before serial number13154 were not adjustable whenthey were shipped from thefactory. If the ECM has beenupdated to revision "BO" or later,or if the machine serial number isafter 13153, you can access therevision level of the ECM by usingthe following procedure.
1 Turn the key switch to ground control and pullout the red Emergency Stop button to the ON
position at both platform and ground controls.
2 Move and hold the function enable toggle switchand the platform up/down toggle switch in thedown direction.
Result: The revision level of the ECM willappear in the diagnostic display window.
1-3Function Speed Tuning(before serial number GS6803-42382)
The raised drive speed and platform lift speeds aredetermined by the percentage of total ECM voltageoutput. The speeds of the these functions may beadjusted to compensate for wear in the hydraulicpump and drive motors.
To adjust the function speeds on machines afterserial number GS6803-42382, see 7-2,Function Speed Tuning (after serial numberGS6803-42381).
For further information or assistance, consult theGenie Industries Service Department.
Tip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingdrive speed greater thanspecifications could cause themachine to tip over resulting indeath or serious injury.
Tip-over hazard. This proceduremust only be performed by atrained service professional.Attempting this procedure withoutthe necessary skills will result indeath or serious injury.
Select a test area that is firm, leveland free of obstructions.
PLATFORM CONTROLS
a diagnostic display windowb red Emergency Stop Button P1c platform up/down toggle switch TS66c function enable toggle switch TS67
d c
20 AMP
SYSTEM
HOUR METER
Refer to the appropriate
Genie service manual
for code descriptions.
FunctionEnable
Stop
b
a
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Section 4 • Repair Procedures March 2005
REV B
4 - 6 GS-2668 RT • GS-3268 RT Part No. 52302
How to Adjust the Raised DriveSpeed
Tip-over hazard. Setting drivespeed greater than specificationswill cause the machine to tip overresulting in death or serious injury.Do not adjust the drive speedhigher than specified in thisprocedure.
The drive function of theGS-2668 RT before serial number26563 is disabled when theplatform is 20 feet / 6.1 m orhigher while the platform isextended. The GS-2668 RT afterserial number 26562 is able todrive at full height due to additionalcounterweight being added to themachine.
The drive function of theGS-3268 RT before serial number42000 is disabled when theplatform is 26 feet / 7.9 m orhigher while the platform isextended. The GS-3268 RT afterserial number 41999 is able todrive at full height due to additionalcounterweight being added to themachine.
1 Remove the platform controls from the platformand place the controls near the diagnosticdisplay window at the ground control panel.
2 Turn the key switch to the off position.
®
Stop
STOP
®
Stop
STOP
AUTOLEVEL
b
c
c
b
a
a
PLATFORM CONTROLS
a steer rocker switch SW6b horn button BN5c platform extend/retract enable BN16
OR outrigger enable button BN16
3 Models without outriggers: Press and holdthe horn button and platform extend/retractenable button, then turn the key switch toplatform controls.
Models with outriggers: Press and hold thehorn button and the outrigger enable button,then turn the key switch to platform controls.
Result: The diagnostic display window at theground controls will show PS.
The PS showing in the diagnosticdisplay window indicates that theECM is in the programming mode.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 7
4 Release the horn button and the platformextend/retract enable button or outrigger enablebutton.
5 Press the horn button to show the maximumraised drive speed percentage.
6 To increase or decrease the raised drive speed,press and hold the horn button while using thesteering rocker switch to adjust the percentage.The percentage will be seen in the diagnosticdisplay window.
Factory percentage settings
Raised drive speedGasoline/LPG models 39Diesel models 42
7 Release the horn button.
8 Turn the key switch to the off position to savethe settings.
9 Confirm the raised drive speed of the machine.Refer to Maintenance Procedure B-11, Test theDrive Speed - Raised Position.
PLATFORM CONTROLS
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Section 4 • Repair Procedures March 2005
REV B
4 - 8 GS-2668 RT • GS-3268 RT Part No. 52302
PLATFORM CONTROLS
How to Adjust the Fast Lift Speed1 Remove the platform controls from the platform
and place the controls near the diagnosticdisplay at the ground control panel.
2 Turn the key switch to the off position.
3 Models without outriggers: Press and holdthe horn button and platform extend/retractenable button, then turn the key switch toplatform controls.
Models with outriggers: Press and hold thehorn button and the outrigger enable button,then turn the key switch to platform controls.
Result: The diagnostic display window at theground controls will show PS.
The PS showing in the diagnosticdisplay window indicates that theECM is in the programming mode.
4 Release the horn button and the platformextend/retract enable button or outrigger enablebutton.
5 Press and hold the function enable/high speedselect button to show the fast platform lift speedpercentage in the diagnostic display window.
6 To increase or decrease the fast platform liftspeed, press and hold the function enable/highspeed select button while using the steeringrocker switch to adjust the percentage.
7 Release the function enable/high speed selectbutton.
a steer rocker switch SW6b function enable/high speed
select button BN12c horn button BN 5d platform extend/retract enable BN16
OR outrigger enable button BN16
8 Turn the key switch to the off position to savethe settings.
9 Confirm the lift speed of the machine. Refer toSection 2, Specifications.
Factory percentage settings
Fast lift speedGasoline/LPG models 39Diesel models 42
®
Stop
STOP
®
Stop
STOP
AUTOLEVEL
d
c
a
a
bb cd
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 9
How to Adjust the Slow LiftSpeed1 Remove the platform controls from the platform
and place the controls near the diagnosticdisplay at the ground control panel.
2 Turn the key switch to the off position.
3 Models without outriggers: Press and holdthe horn button and platform extend/retractenable button, then turn the key switch toplatform controls.
Models with outriggers: Press and hold thehorn button and the outrigger enable button,then turn the key switch to platform controls.
Result: The diagnostic display window at theground controls will show PS.
The PS showing in the diagnosticdisplay window indicates that theECM is in the programming mode.
4 Release the horn button and the platformextend/retract enable button or outrigger enablebutton.
5 Press and hold the function enable/high speedselect button to show the fast platform lift speedpercentage in the diagnostic display window.Note this number.
6 Press and hold the function enable/low speedselect button to show the platform lift slowspeed percentage in the diagnostic displaywindow.
a steer rocker switch SW6b function enable/low speed
select button BN13c horn button BN5d platform extend/retract enable BN16
OR outrigger enable button BN16
7 To increase or decrease the platform lift speed,press and hold the function enable/slow speedselect button while using the steering rockerswitch to adjust the percentage.
The Slow Lift Speed percentageshould be set 4 to 6 points lessthan the Fast Lift Speedpercentage.
8 Release the function enable/slow speed selectbutton.
9 Turn the key switch to the off position to savethe settings.
Factory percentage settings
Slow lift speedGasoline/LPG models 34Diesel models 38
PLATFORM CONTROLS
®
Stop
STOP
®
Stop
STOP
AUTOLEVEL
d
c
a
a
bb cd
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Section 4 • Repair Procedures March 2005
REV B
4 - 10 GS-2668 RT • GS-3268 RT Part No. 52302
PLATFORM CONTROLS
1-4Software Configuration(before serial number GS6803-42382)
The Electronic Control Module (ECM) containsprogramming for all configurations of the GS68 RT.
Models before serial number GS6803-42382 canbe adjusted to a different configuration by changingthe combination of the DIP switch settings, locatedon the circuit board inside the platform control box.DIP switches have two positions - on or off. Whenreading the DIP switch code in the DIP SwitchCodes Chart on the next page, the on and off arerepresented by the numbers 1 (on) and 0 (off).
How to Determine the DIP SwitchConfiguration1 Turn the key switch to ground control and pull
out the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.
2 Move and hold the platform up/down toggleswitch in the up direction and activate thefunction enable toggle switch from the groundcontrols.
Result: The diagnostic display window locatedon the ground control panel, will display aconfiguration number without the dotilluminated. This configuration number indicatesthe current configuration of the machine.
Configuration code that is lessthan 100 will be shown as aconstant display. Configurationcode that is greater than 99 will beshown as a flashing display.
How to Configure the SoftwareIf replacing the circuit board, notethe position of each of the 8 toggleswitches on the DIP switch block.Set the DIP switch on the newcircuit board to the sameconfiguration of the old one.
If replacing the circuit board, usedielectric grease on the DIP switchand all plug-in connectors.
1 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols. Turn the key switch to the off position.
2 Remove the fasteners securing the lid of theplatform controls and open the platform controlbox.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 11
PLATFORM CONTROLS
3 Rotate the platform control box in the positionshown to correctly identify the configuration ofthe DIP switch settings.
7 To confirm the settings, pull out the redEmergency Stop button to the on position atboth the ground and platform controls and turnthe key switch to ground control. Do not startthe engine.
8 Move and hold the platform up/down toggleswitch in the up direction and activate thefunction enable toggle switch from the groundcontrols.
Result: The diagnostic display window locatedon the ground control panel, will display aconfiguration number without the dotilluminated. This configuration number indicatesthe current configuration of the machine.
Configuration code that is lessthan 100 will be shown as aconstant display. Configurationcode that is greater than 99 will beshown as a flashing display.
b
f
e
a
c
dON (1)
1 2 3 4 5 6 7 8
ON DIP
OFF (0)
d c
20 AMP
SYSTEM
HOUR METER
Refer to the appropriate
Genie service manual
for code descriptions.
FunctionEnable
Stop
b
a
a red Emergency Stop button P2b DIP switch SW25c control boxd enlarged view of DIP switch SW25e circuit board U3f joystick controller JC4
4 Locate the DIP switch on the printed circuitboard. Move the DIP switch settings tocorrespond with the configuration of themachine options indicated in the chart.See 1-4, Software Configuration.
5 Apply dielectric grease to the DIP switch aftersetting the configuration.
6 Close the lid and install the platform control boxlid fasteners.
a diagnostic display windowb red Emergency Stop Button P1c platform up/down toggle switch TS66c function enable toggle switch TS67
9 Release the toggle switches, push in the redEmergency Stop button to the off position atboth the ground and platform controls and turnthe key switch to the off position.
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Section 4 • Repair Procedures March 2005
REV B
4 - 12 GS-2668 RT • GS-3268 RT Part No. 52302
PLATFORM CONTROLS
DIP Switch Codes ChartA • in the column indicate that the machineconfiguration includes this option.
Lift/
Driv
e C
ut O
ut
No
Sim
ulta
neou
sO
pera
tion
DiagnosticDisplayCode
DIPSwitchCode
Gas
olin
e/LP
G
Die
sel
Mot
ion
Ala
rm
Mot
ion
Bea
con
Ove
rload
Sen
sor
Des
cent
Del
ay
01 01011010 •02 00111010 •04 01010001 • •05 10100110 • •07 01011011 • •08 00111011 • •10 01010000 • • •11 10100111 • • •13 01010100 • •14 00110000 • •16 00100100 • • •17 10100100 • • •19 01011000 • • •20 00111000 • • •22 00101100 • • • •23 10101100 • • • •25 01010011 • •26 00110011 • •28 00100101 • • •29 10100101 • • •31 01010111 • • •32 00110111 • • •34 00101001 • • •35 10101001 • • •37 01011100 • • • •38 00111100 • • • •40 00101101 • • • •41 10101101 • • • •43 01011111 • • • •44 00111111 • • • •46 00101111 • • • • •47 10101111 • • • • •
No
Sim
ulta
neou
sO
pera
tion
DiagnosticDisplayCode
DIPSwitchCode
Gas
olin
e/LP
G
Die
sel
Mot
ion
Ala
rm
Lift/
Driv
e C
ut O
ut
Mot
ion
Bea
con
Ove
rload
Sen
sor
Des
cent
Del
ay
49 01110000 • •50 10000000 • •52 01110001 • • •53 10000001 • • •55 01110010 • • •56 10000010 • • •58 10011111 • • •59 01111111 • • •61 01110111 • • •62 01111000 • • •64 10011000 • • • •65 10011001 • • • •67 01110011 • • • •68 10001011 • • • •70 10001101 • • • •71 01111100 • • • •73 10011011 • • • •74 10000111 • • • •76 01110100 • • • •77 10010011 • • • •79 01110110 • • • •80 00011010 • • • •82 10000100 • • • • •83 10001100 • • • • •85 01110101 • • • • •86 10000110 • • • • •88 10000101 • • • • •89 10011110 • • • • •91 10001000 • • • • •92 00011100 • • • • •94 01111011 • • • • • •95 10011100 • • • • • •
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 13
PLATFORM CONTROLS
No
Sim
ulta
neou
sO
pera
tion
DiagnosticDisplayCode
DIPSwitchCode
Gas
olin
e/LP
G
Die
sel
Mot
ion
Ala
rm
Lift/
Driv
e C
ut O
ut
Mot
ion
Bea
con
Ove
rload
Sen
sor
Des
cent
Del
ay
97 00010000 • •98 00010001 • •
100 00010011 • • •101 00010100 • • •103 00010110 • • •104 00010111 • • •106 00011001 • • • •107 01111010 • • • •109 00101000 • • •110 00011101 • • •112 00011111 • • • •113 00000000 • • • •115 00000010 • • • •116 00000011 • • • •118 00000101 • • • • •119 00000110 • • • • •121 00001000 • • •122 00001001 • • •124 00001011 • • • •125 00001100 • • • •127 00001110 • • • •128 00001111 • • • •130 00100001 • • • •131 00100010 • • • •133 00100110 • • • • •134 00100111 • • • • •136 00101011 • • • • •137 00101110 • • • • •139 00110010 • • • • •140 00110100 • • • • •142 00110110 • • • • • •143 00111001 • • • • • •
DiagnosticDisplayCode
DIPSwitchCode
Gas
olin
e/LP
G
Die
sel
Mot
ion
Ala
rm
Lift/
Driv
e C
ut O
ut
Mot
ion
Bea
con
Ove
rload
Sen
sor
Des
cent
Del
ay
No
Sim
ulta
neou
sO
pera
tion
145 00111110 • • •146 01000000 • • •148 01000010 • • • •149 01000011 • • • •151 01000101 • • • •152 01000110 • • • •154 01001000 • • • •155 01001001 • • • •157 01001011 • • • •158 01001100 • • • •160 01001110 • • • • •161 01001111 • • • • •163 01010101 • • • • •164 01010110 • • • • •166 01011101 • • • • •167 01011110 • • • • •169 01100001 • • • • •170 01100010 • • • • •172 01100110 • • • • •173 01100111 • • • • •175 01101110 • • • • •176 10100000 • • • • •178 10100010 • • • • • •179 10100011 • • • • • •181 10101010 • • • • • •182 10101011 • • • • • •184 10110000 • • • • • •185 10110001 • • • • • •187 10110011 • • • • • •188 10110100 • • • • • •190 10110110 • • • • • • •191 10110111 • • • • • • •
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Section 4 • Repair Procedures March 2005
REV A
4 - 14 GS-2668 RT • GS-3268 RT Part No. 52302
2-1Platform
How to Remove the PlatformBodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.
Perform this procedure with theplatform in the stowed positionand the platform extension deckfully retracted and locked inposition.
1 Start the engine from the ground controls andraise the platform 9 to 10 feet / 2.7 to 3 m.
2 Lift the safety arm, move it to the center of thescissor arm and rotate down to a verticalposition.
3 Lower the platform onto the safety arm. Turnthe machine off.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
4 Remove the hose clamps or zip ties that securethe power to platform wiring to the bottom of theplatform.
Component damage hazard. Besure not to cut the power toplatform wiring.
5 GS-2668 RT before serial number 26563 andGS-3268 RT before serial number 41200:Remove the platform extension limit switchmounting fasteners and remove the limit switch.Do not disconnect the wiring.
6 Raise the platform and return the safety arm tothe stowed position.
7 Lower the platform to the stowed position andturn the machine off.
8 Remove the mounting fasteners that secure theplatform controls quick disconnect plug to theplatform.
9 Twist the connector to disconnect the platformcontrols from the plug.
10 Remove the platform control box from theplatform and lay it off to the side.
Component damage hazard. Theplatform controls wiring can bedamaged if it is kinked or pinched.
11 Remove the cover to the AC power to platformoutlet. Tag and disconnect the wiring from theoutlet.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
12 Pull the wiring down through the platform tube.
Component damage hazard. TheAC power to platform wiring canbe damaged if it is kinked orpinched.
If your machine is equipped withan air line to platform option, theair line must be disconnected fromthe platform before removal.
Platform Components
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Section 4 • Repair ProceduresMarch 2005
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 15
PLATFORM COMPONENTS
13 Support the platform with a forklift at thesteer end of the machine. Do not apply anylifting pressure.
14 Attach a strap from the platform railings to thecarriage on the forklift to support the platform.
15 Remove the retaining fasteners from theplatform pivot pins at the steer end of themachine.
16 Use a slide hammer to remove the pins.
Crushing hazard. The platform willfall when the pivot pins areremoved if not properly supportedby the forklift.
17 Remove the retaining fasteners from theplatform pivot pins at the non-steer end of themachine.
18 Use a slide hammer to remove the pins.
Crushing hazard. The platform willfall when the pivot pins areremoved if not properly supportedby the forklift.
19 Carefully lift the platform off of the machine andplace it on a structure capable of supporting it.
Crushing hazard. The platform willbecome unbalanced and fall whenremoved from the machine if notproperly supported and secured tothe forklift.
Note the position of the wear padsbefore the platform is removed sothat when the platform is installedthey will be in the correct position.
2-2Platform Extension Deck
How to Remove the PlatformExtension Deck
Perform this procedure with theplatform in the stowed positionand the platform extension deckfully retracted and locked inposition.
1 Remove the fasteners from the access cover onthe side of the platform at the non-steer end ofthe machine.
2 Remove the fasteners from the roller wheelmount.
3 Remove the wheel roller bolt, then remove theroller wheel from the platform.
4 Repeat steps 2 through 4 for the other side ofthe platform.
5 Lift the platform extension lock handle.
6 Remove the two bolts that attach the platformextension lock handle assembly to the platformextension railing.
7 Remove the two bolts that attach the extensionlock pin bracket to the railing. Lay the lockhandle assembly off to the side.
8 Remove the platform extension limit switchmounting fasteners and remove the limit switch.Do not disconnect the wiring.
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Section 4 • Repair Procedures March 2005
REV A
4 - 16 GS-2668 RT • GS-3268 RT Part No. 52302
PLATFORM COMPONENTS
9 GS-2668 RT before serial number 26563 andGS-3268 RT before serial number 41200:Remove the platform extension limit switchmounting fasteners and remove the limit switch.Do not disconnect the wiring.
10 Remove the platform controls from the platformand lay them off to the side.
11 Position a forklift at the steer end of themachine with the forks even with the bottom ofthe platform extension.
12 Carefully slide the platform extension out untilthe platform extension makes contact with thecarriage on the forklift.
13 Attach a lifting strap from the platform extensionrailings to the carriage on the forklift to supportthe platform extension.
14 Carefully slide the platform extension out andaway from the platform and place it on astructure capable of supporting it.
Crushing hazard. The platformextension will become unbalancedand fall when removed from themachine if not properly supportedand secured to the forklift.
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Section 4 • Repair ProceduresMarch 2005
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 17
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Section 4 • Repair Procedures March 2005
REV B
4 - 18 GS-2668 RT • GS-3268 RT Part No. 52302
Scissor Components
GS-2668
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1 Number 5 pivot pin (steer end)2 Number 4 center pivot pin3 Number 4 pivot pin (steer end)4 Number 3 outer arm5 Lift cylinder rod-end pivot pin6 Number 3 pivot pin (steer end)7 Number 2 center pivot pins (2 each)8 Number 2 pivot pin (steer end)9 Number 1 center pivot pin10 Number 1 inner arm11 Number 1 pivot pin(s) (steer end)12 Number 5 pivot pin (non-steer end)
13 Number 4 inner arm14 Number 4 outer arm15 Number 4 pivot pin (non-steer end)16 Number 3 inner arm17 Number 3 center pivot pin18 Number 3 pivot pin (non-steer end)19 Number 2 inner arm20 Number 2 outer arm21 Number 2 pivot pin (non-steer end)22 Lift cylinder barrel-end pivot pin23 Number 1 outer arm
Non-steer EndSteer End
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 19
SCISSOR COMPONENTS
3-1Scissor Assembly, GS-2668 RT
How to Disassemble theScissor Assembly, GS-2668 RT
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
1 Remove the platform. See 2-1, How to Removethe Platform.
2 Remove the cables from the number 4 outerarm (index #14).
3 Remove the cables from the upper cable traysupport.
4 Remove the cables from the number 3 innerarm (index #16) and lay the cables off to theside.
Component damage hazard.Cables can be damaged if theyare kinked or pinched.
5 Remove the mounting fasteners from the uppercable tray supports.
6 Remove the upper cable tray from the scissorassembly.
Component damage hazard.Cables can be damaged if theyare kinked or pinched.
7 Connect the platform controls to the quickdisconnect plug to allow the machine tooperate.
8 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols. Start the engine.
9 Raise the platform approximately 10 feet / 3 m.
10 Remove the safety arm from the number 3 innerarm (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 thescissor arm and rotate down to a verticalposition.
13 Lower the scissor assembly onto the safetyarm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
14 Turn the key switch to the off position and pushin the red Emergency Stop button to the offposition at both the ground and platformcontrols.
15 Attach a lifting strap from an overhead crane tothe number 4 outer arm (index #14).
16 Support the number 4 inner arm (index #13)with a second overhead crane at the non-steerend.
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Section 4 • Repair Procedures March 2005
REV B
4 - 20 GS-2668 RT • GS-3268 RT Part No. 52302
SCISSOR COMPONENTS
17 Remove the external snap rings from thenumber 4 center pivot pin (index #2).
18 Use a soft metal drift to remove the number 4center pivot pin (index #2).
19 Remove the external snap rings from thenumber 4 pivot pin (index #15) at the non-steerend of the machine.
20 Use a soft metal drift to remove the number 4pivot pin (index #15) from the non-steer end.Remove the number 4 outer arm (index #14)from the machine.
Crushing hazard. The number 4outer arm (index #14) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
21 Attach a lifting strap from an overhead crane tothe number 4 inner arm (index #13).
22 Remove the external snap rings from thenumber 4 pivot pin (index #3).
23 Use a soft metal drift to remove the number 4pivot pin (index #3). Remove the number 4inner arm (index #13) from the machine.
Crushing hazard. The number 4inner arm (index #13) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
24 Attach a lifting strap from an overhead crane tothe number 3 outer arm (index #4) at theground controls side.
25 Support the number 3 inner arm (index #16)with a second overhead crane at the non-steerend.
26 Remove the external snap rings from thenumber 3 center pivot pin (index #17) at theground controls side.
27 Use a soft metal drift to tap the number 3 centerpivot pin (index #17) halfway out at the groundcontrols side.
28 Remove the external snap rings from thenumber 3 pivot pin (index #18) at the non-steerend.
29 Use a soft metal drift to tap the number 3 pivotpin (index #18) halfway out at the non-steer endof the machine. Remove the number 3 outerarm (index #4) at the ground controls side fromthe machine.
Crushing hazard. The number 3outer arm (index #4) at the groundcontrols side could becomeunbalanced and fall if not properlysupported when removed from themachine.
30 Attach a lifting strap from an overhead crane tothe number 3 outer arm (index #4) at the engineside.
31 Remove the external snap rings from thenumber 3 center pivot pin (index #17) at theengine side.
32 Use a soft metal drift to tap the number 3 centerpivot pin (index #17) at the engine side in theother direction.
33 Use a soft metal drift to tap the number 3 pivotpin (index #18) at the non-steer end in the otherdirection. Remove the number 3 outer arm(index #4) from the engine side of the machine.
Crushing hazard. The number 3outer arm (index #4) at the engineside could become unbalancedand fall if not properly supportedwhen removed from the machine.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 21
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 lowercable tray mounting bracket on the number 2center pivot pin (index #7) at the engine side ofthe machine.
36 Remove the mounting fasteners from the lowercable tray supports at both ends of the lowercable tray.
37 Remove the lower cable tray from the machine.
Component damage hazard.Cables can be damaged if theyare kinked or pinched.
38 Attach a lifting strap from an overhead crane tothe lug on the rod end of the lift cylinder.
39 Remove the pin retaining fasteners from thecylinder rod-end pivot pin (index #5). Use a softmetal drift to remove the pin.
Crushing hazard. The cylindercould fall if not properly supportedwhen the pin is removed.
40 Lower the cylinder onto the number 1 centerpivot pin (index #9).
41 Remove the external snap rings from thenumber 3 pivot pin (index #6) at the steer end.
42 Use a soft metal drift to remove the number 3pivot pin (index #6) at the steer end. Removethe number 3 inner arm (index #16) from themachine.
Crushing hazard. The number 3inner arm (index #16) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
43 Attach a lifting strap from an overhead crane tothe number 2 outer arm (index #20) at theground controls side.
44 Support the number 2 inner arm (index #19)with a second overhead crane at the non-steerend.
45 Remove the external snap rings from thenumber 2 center pivot pin (index #7) at theground controls side.
46 Use a soft metal drift to remove the number 2center pivot pin (index #7) at the groundcontrols side.
47 Remove the external snap rings from thenumber 2 pivot pin (index #21) at the non steerend.
48 Use a soft metal drift to tap the number 2 pivotpin (index #21) halfway out at the non-steer endof the machine. Remove the number 2 outerarm (index #20) at the ground controls sidefrom the machine.
Crushing hazard. The number 2outer arm (index #20) at theground controls side couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
49 Attach a lifting strap from an overhead crane tothe number 2 outer arm (index #20) at theengine side.
50 Remove the external snap rings from thenumber 2 center pivot pin (index #7) at theengine side.
51 Use a soft metal drift to remove the number 2center pivot pin (index #7) at the engine side.
SCISSOR COMPONENTS
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Section 4 • Repair Procedures March 2005
REV B
4 - 22 GS-2668 RT • GS-3268 RT Part No. 52302
SCISSOR COMPONENTS
52 Use a soft metal drift to tap the number 2 pivotpin (index #21) at the non steer end in the otherdirection. Remove the number 2 outer arm(index #20) from the engine side of themachine.
Crushing hazard. The number 2outer arm (index #20) at theengine side could becomeunbalanced and fall if not properlysupported when removed from themachine.
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 thenumber 2 pivot pin (index #8) at the steer end.
55 Use a soft metal drift to remove the number 2pivot pin (index #8) at the steer end. Removethe number 2 inner arm (index #19) from themachine.
Crushing hazard. The number 2inner arm (index #19) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
56 Tag, disconnect and plug the hydraulic hose onthe lift cylinder. Cap the fitting on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
57 Tag and disconnect the wiring from the solenoidvalve on the lift cylinder.
58 Remove the cables from the number 1 innerarm (index #10). Lay the cables off to the sideof the machine.
Component damage hazard.Cables can be damaged if theyare kinked or pinched.
59 Remove the LPG tank.
60 Remove the LPG tank bracket mountingfasteners. Remove the LPG tank bracket fromthe machine.
61 Raise the scissor assembly slightly and returnthe safety arm to the stowed position. Lowerthe scissor assembly.
Crushing hazard. The scissorassembly could becomeunbalanced and fall if not properlysupported when the safety arm isreturned to the stowed position.
62 Support and secure the entry ladder to anappropriate lifting device. Remove the entryladder mounting fasteners. Remove the entryladder from the machine.
Crushing hazard. The entry laddercould become unbalanced and fallif not properly supported andsecured to the lifting device.
63 Secure both ends of the scissor arms togetherwith a strap or other suitable device.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 23
64 Attach each end of a lifting strap to each end ofthe scissor assembly.
65 Attach an overhead crane to the center of thestrap.
66 Remove the pin retaining fasteners from thenumber 1 pivot pin(s) (index #11). Use a softmetal drift to remove the pin(s).
Crushing hazard. The scissorassembly could fall if not properlysupported by the overhead crane.
67 Lift the scissor assembly slightly and slide thescissor assembly towards the non-steer end ofthe machine to allow the wear pads to slide outof the channel.
68 Remove the scissor assembly from themachine and place it on a structure capable ofsupporting it.
Crushing hazard. The scissorassembly could becomeunbalanced and fall if not properlysupported and secured to theoverhead crane.
During removal, the lifting strapconnected to the overhead cranewill need to be carefully adjustedfor proper balancing.
69 Remove the straps securing the scissor armstogether.
70 Attach a lifting strap from an overhead crane tothe lug on the rod end of the lift cylinder. Raisethe rod end of the cylinder to a vertical position.
71 Remove the pin retaining fasteners from thecylinder barrel-end pivot pin (index #22). Use asoft metal drift to remove the pin. Remove thecylinder from the scissor assembly.
Crushing hazard. The cylindercould become unbalanced and fallif not properly supported whenremoved from the assembly.
72 Attach a lifting strap from an overhead crane tothe 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 thenumber 1 center pivot pin (index #9).
75 Use a soft metal drift to remove the number 1center pivot pin (index #9).
Crushing hazard. The scissorassembly could becomeunbalanced and fall if not properlysupported when the center pivotpin is removed.
76 Remove the number 1 outer arm (index #23)from the assembly.
Crushing hazard. The number 1inner arm (index #10) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
SCISSOR COMPONENTS
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Section 4 • Repair Procedures March 2005
REV B
4 - 24 GS-2668 RT • GS-3268 RT Part No. 52302
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1 Number 6 pivot pin (steer end)2 Number 5 center pivot pin3 Upper lift cylinder rod-end pivot pin4 Number 5 pivot pin (steer end)5 Number 4 center pivot pins (2 each)6 Number 4 pivot pin (steer end)7 Number 3 outer arm8 Number 3 center pivot pin9 Lower lift cylinder rod-end pivot pin10 Number 3 pivot pin (steer end)11 Number 2 center pivot pins (2 each)12 Number 2 pivot pin (steer end)13 Number 1 center pivot pin14 Number 1 inner arm15 Number 1 pivot pin(s) (steer end)
16 Number 6 pivot pin (non-steer end)17 Number 5 inner arm18 Number 5 outer arm19 Number 5 pivot pin (non-steer end)20 Number 4 inner arm21 Number 4 outer arm22 Number 4 pivot pin (non-steer end)23 Upper lift cylinder barrel-end pivot pin24 Number 3 inner arm25 Number 3 pivot pin (non-steer end)26 Number 2 inner arm27 Number 2 outer arm28 Number 2 pivot pin (non-steer end)29 Lower lift cylinder barrel-end pivot pin30 Number 1 outer arm
Non-steer EndSteer End
SCISSOR COMPONENTS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 25
SCISSOR COMPONENTS
3-2Scissor Assembly, GS-3268 RT
How to Disassemble theScissor Assembly, GS-3268 RT
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is required.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
1 Remove the platform. See 2-1, How to Removethe Platform.
2 Remove the cables from the side of the number5 outer arm (index #18) at the engine side.
Component damage hazard.Cables can be damaged if theyare kinked or pinched.
3 Attach a lifting strap from an overhead crane tothe number 5 outer arm (index #18).
4 Remove the external snap rings from thenumber 5 center pivot pin (index #2).
5 Use a soft metal drift to remove the number 5center pivot pin (index #2).
6 Remove the external snap rings from thenumber 5 pivot pin (index #19) at the non-steerend.
7 Use a soft metal drift to remove the number 5pivot pin (index #19) from the non-steer end ofthe machine. Remove the number 5 outer arm(index #18) from the machine.
Crushing hazard. The number 5outer arm (index #18) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
8 Remove the cable clamps from the number 5inner arm (index #17) and the upper cable tray.Lay the cables off to the side of the machine.
Component damage hazard.Cables can be damaged if theyare kinked or pinched.
9 Tag, disconnect and plug the hydraulic hose onthe upper lift cylinder. Cap the fitting on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
10 Attach a lifting strap from an overhead crane tothe lug on the rod end of the upper lift cylinder.
11 Remove the pin retaining fasteners from theupper cylinder rod-end pivot pin (index #3). Usea soft metal drift to remove the pin.
Crushing hazard. The cylindercould fall if not properly supportedwhen the pin is removed.
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Section 4 • Repair Procedures March 2005
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4 - 26 GS-2668 RT • GS-3268 RT Part No. 52302
SCISSOR COMPONENTS
12 Lower the cylinder onto the number 3 centerpivot pin (index #8).
13 Attach a lifting strap from an overhead crane tothe number 5 inner arm (index #17).
14 Remove the external snap rings from thenumber 5 pivot pin (index #4).
15 Use a soft metal drift to remove the number 5pivot pin (index #4). Remove the number 5inner arm (index #17) from the machine.
Crushing hazard. The number 5inner arm (index #17) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
16 Remove the mounting fasteners from the uppercable tray mounting bracket on the number 4center pivot pin (index #5) at the engine side ofthe machine.
17 Remove the mounting fasteners from the uppercable tray supports at both ends of the uppercable tray.
18 Remove the upper cable tray.
19 Tag and disconnect the wiring from the solenoidvalve on the lift cylinder.
20 Remove the safety arm from the number 4 innerarm (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 quickdisconnect plug to allow the machine tooperate.
23 Turn the key switch to ground control and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols. Start the engine.
24 Raise the platform approximately 10 feet / 3 m.
25 Lift the safety arm, move it to the center of thescissor arm and rotate down to a verticalposition. Lower the scissor assembly onto thesafety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
26 Turn the key switch to the off position and pushin the red Emergency Stop buttons to the offposition at both the ground and platformcontrols.
27 Attach a lifting strap from an overhead crane tothe number 4 outer arm (index #21) at theground controls side.
28 Support the number 4 inner arm (index #20)with a second overhead crane at the non-steerend.
29 Remove the external snap rings from thenumber 4 center pivot pin (index #5) at theground controls side.
30 Use a soft metal drift to remove the number 4center pivot pin (index #5) at the groundcontrols side.
31 Remove the external snap rings from thenumber 4 pivot pin (index #22) at the non-steerend.
32 Use a soft metal drift to tap the number 4 pivotpin (index #22) halfway out at the non-steer endof the machine. Remove the number 4 outerarm (index #21) at the ground controls sidefrom the machine.
Crushing hazard. The number 4outer arm (index #21) at theground controls side couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
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Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 27
33 Attach a lifting strap from an overhead crane tothe number 4 outer arm (index #21) at theengine side.
34 Remove the external snap rings from thenumber 4 center pivot pin (index #5) at theengine side.
35 Use a soft metal drift to remove the number 4center pivot pin (index #5) at the engine side.
36 Use a soft metal drift to tap the number 4 pivotpin (index #22) in the other direction. Removethe number 4 outer arm (index #21) from theengine side of the machine.
Crushing hazard. The number 4outer arm at the engine side(index #21) could becomeunbalanced and fall if not properlysupported when removed from themachine.
37 Remove the external snap rings from thenumber 4 pivot pin (index #6) at the steer endof the machine.
38 Use a soft metal drift to remove the number 4pivot pin (index #6) at the steer end. Removethe number 4 inner arm (index #20) from themachine.
Crushing hazard. The number 4inner arm (index #20) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
39 Attach a lifting strap from an overhead crane tothe lug on the rod end of the upper lift cylinder.Raise the rod end of the cylinder to a verticalposition.
40 Remove the pin retaining fasteners from theupper cylinder barrel-end pivot pin (index #23).Use a soft metal drift to remove the pin.Remove the cylinder from the machine.
Crushing hazard. The cylindercould become unbalanced and fallwhen removed from the machine ifnot properly supported.
Component damage hazard. Becareful not to damage the valve orfittings on the cylinder whileremoving it from the machine.
41 Attach a lifting strap from an overhead crane tothe number 3 outer arm (index #7) at theground controls side.
42 Support the number 3 inner arm (index #24)with a second overhead crane at the non-steerend.
43 Remove the external snap rings from thenumber 3 center pivot pin (index #8) at theground controls side.
44 Use a soft metal drift to tap the number 3 centerpivot pin (index #8) halfway out at the groundcontrols side.
45 Remove the external snap rings from thenumber 3 pivot pin (index #25) at the non steerend.
46 Use a soft metal drift to tap the number 3 pivotpin (index #25) halfway out at the non-steer endof the machine. Remove the number 3 outerarm (index #7) at the ground controls side fromthe machine.
Crushing hazard. The number 3outer arm (index #7) at the groundcontrols side could becomeunbalanced and fall if not properlysupported when removed from themachine.
SCISSOR COMPONENTS
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SCISSOR COMPONENTS
47 Attach a lifting strap from an overhead crane tothe number 3 outer arm (index #7) at the engineside.
48 Remove the external snap rings from thenumber 3 center pivot pin (index #8) at theengine side.
49 Use a soft metal drift to tap the number 3 centerpivot pin (index #8) at the engine side in theother direction.
50 Use a soft metal drift to tap the number 3 pivotpin (index #25) at the non-steer end in the otherdirection. Remove the number 3 outer arm(index #7) from the engine side of the machine.
Crushing hazard. The number 3outer arm (index #7) at the engineside could become unbalancedand fall if not properly supportedwhen removed from the machine.
51 Remove the cables from the number 3 innerarm (index #24). Lay the cables off to the sideof 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 lowercable tray mounting bracket on the number 2center pivot pin (index #11) at the engine sideof the machine.
54 Remove the mounting fasteners from the lowercable tray supports at both ends of the lowercable tray.
55 Remove the lower cable tray from the machine.
Component damage hazard.Cables can be damaged if theyare kinked or pinched.
56 Attach a lifting strap from an overhead crane tothe lug on the rod end of the lower lift cylinder.
57 Remove the pin retaining fasteners from thelower cylinder rod-end pivot pin (index #9). Usea soft metal drift to remove the pin.
Crushing hazard. The cylindercould fall if not properly supportedwhen the pin is removed.
58 Lower the cylinder onto the number 1 centerpivot pin (index #13).
59 Remove the external snap rings from thenumber 3 pivot pin (index #10) at the steer end.
60 Use a soft metal drift to remove the number 3pivot pin (index #10) at the steer end. Removethe number 3 inner arm (index #24) from themachine.
Crushing hazard. The number 3inner arm (index #24) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
61 Attach a lifting strap from an overhead crane tothe number 2 outer arm (index #27) at theground controls side.
62 Support the number 2 inner arm (index #26)with a second overhead crane at the non-steerend.
63 Remove the external snap rings from thenumber 2 center pivot pin (index #11) at theground controls side.
64 Use a soft metal drift to remove the number 2center pivot pin (index #11) at the groundcontrols side.
65 Remove the external snap rings from thenumber 2 pivot pin (index #28) at the non steerend.
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Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 29
66 Use a soft metal drift to tap the number 2 pivotpin (index #28) halfway out at the non-steer endof the machine. Remove the number 2 outerarm (index #27) at the ground controls sidefrom the machine.
Crushing hazard. The number 2outer arm (index #27) at theground controls side couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
67 Attach a lifting strap from an overhead crane tothe number 2 outer arm (index #27) at theengine side.
68 Remove the external snap rings from thenumber 2 center pivot pin (index #11) at theengine side.
69 Use a soft metal drift to remove the number 2center pivot pin (index #11) at the engine side.
70 Use a soft metal drift to tap the number 2 pivotpin (index #28) at the non-steer end in the otherdirection. Remove the number 2 outer arm(index #27) from the engine side of themachine.
Crushing hazard. The number 2outer arm (index #27) at theengine side could becomeunbalanced and fall if not properlysupported when removed from themachine.
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 thenumber 2 pivot pin (index #12) at the steer end.
73 Use a soft metal drift to remove the number 2pivot pin (index #12) at the steer end. Removethe number 2 inner arm (index #26) from themachine.
Crushing hazard. The number 2inner arm (index #26) couldbecome unbalanced and fall if notproperly supported when it isremoved from the machine.
74 Support and secure the entry ladder to anappropriate lifting device. Then remove theentry ladder mounting fasteners. Remove theentry ladder from the machine.
Crushing hazard. The entry laddercould become unbalanced and fallif not properly supported andsecured to the lifting device.
75 Disconnect and plug the hydraulic hose on thelift cylinder. Cap the fitting on the cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
76 Tag and disconnect the wiring from the solenoidvalve on the lift cylinder.
77 Remove the cables from the number 1 innerarm (index #14). Lay the cables off to the sideof the machine.
78 Remove the LPG tank.
79 Remove the LPG tank bracket mountingfasteners. Remove the LPG tank bracket fromthe machine.
SCISSOR COMPONENTS
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SCISSOR COMPONENTS
80 Raise the scissor assembly slightly and returnthe safety arm to the stowed position. Lowerthe scissor assembly. Remove the straps.
Crushing hazard. The scissorassembly could becomeunbalanced and fall if not properlysupported when the safety arm isreturned to the stowed position.
81 Secure both ends of the scissor arms togetherwith a strap or suitable device.
82 Attach each end of a lifting strap of amplecapacity to each end of the scissor assembly.
83 Attach an overhead crane to the center of thestrap.
84 Remove the pin retaining fasteners from thenumber 1 pivot pin(s) (index #15). Use a softmetal drift to remove the pin(s).
Crushing hazard. The scissorassembly could fall if not properlysupported by the overhead crane.
85 Lift the scissor assembly slightly and slide thescissor assembly towards the non-steer end ofthe machine to allow the wear pads to slide outof the channel.
86 Remove the scissor assembly from themachine and place it on a structure capable ofsupporting it.
Crushing hazard. The scissorassembly could becomeunbalanced and fall if not properlysupported and secured to theoverhead crane.
During removal, the lifting strapconnected to the overhead cranewill need to be carefully adjustedfor proper balancing.
87 Remove the straps securing the scissor armstogether.
88 Attach a lifting strap from an overhead crane tothe lug on the rod end of the lower lift cylinder.Raise the rod end of the cylinder to a verticalposition.
89 Remove the pin retaining fasteners from thelower cylinder barrel-end pivot pin (index #29).Use a soft metal drift to remove the pin.Remove the cylinder from the scissorassembly.
Crushing hazard. The cylindercould become unbalanced and fallif not properly supported whenremoved from the assembly.
90 Attach a lifting strap from an overhead crane tothe 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 thenumber 1 center pivot pin (index #13).
93 Use a soft metal drift to remove the number 1center pivot pin (index #13).
Crushing hazard. The scissorassembly could becomeunbalanced and fall if not properlysupported when removed from themachine.
94 Remove the number 1 outer arm (index #30)from the assembly.
Crushing hazard. The number 1outer arm (index #30) couldbecome unbalanced and fall if notproperly supported when removedfrom the machine.
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Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 31
3-3Wear Pads
How to Replace the Scissor ArmWear Pads1 Remove the platform. See 2-1, How to Remove
the Platform.
2 Remove the mounting fasteners from thestationary wear pads on the platform.
Note the position of the wear padsbefore they are removed so whenthe new ones are installed theywill be in the correct position.
3 Connect the platform controls to the quickdisconnect plug to allow the machine tooperate.
4 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols. Start the engine.
5 Raise the platform approximately 10 feet / 3 m.
6 Lift the safety arm, move it to the center of thescissor arm and rotate down to a verticalposition.
7 Lower the scissor arms onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the scissor arms.
SCISSOR COMPONENTS
8 Turn the key switch to the off position and pushin the red Emergency Stop buttons to the offposition at both the ground and platformcontrols.
9 Secure both ends of the scissor arms togetherwith a strap or other suitable device.
10 Attach a strap from an overhead crane to thenon-steer end of the scissor arms.
11 Raise the scissor arms slightly at the non-steerend with the overhead crane just enough totake the pressure off of the non-steer end slideblocks.
12 Remove the pin retaining fasteners from theslide block pivot pin.
13 Place a rod through the pin and twist to removethe pin.
14 Remove the slide block and remove the wearpad mounting fasteners.
15 Install the new wear pad.
16 Repeat steps 12 through 15 for the other wearpad slide block.
17 Install the wear pad slide blocks into the drivechassis and install the slide block pivot pins andpin retaining fasteners.
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SCISSOR COMPONENTS
3-4Lift Cylinder(s)
The lift cylinders are single acting hydrauliccylinders. The GS-2668 RT uses one lift cylinder;the GS-3268 RT uses two. Each lift cylinder isequipped with a check valve to prevent movementin the event of a hydraulic line failure.
How to Remove the Lift CylinderGS-2668 RT:
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
1 Raise the platform approximately 10 feet / 3 m.
2 Lift the safety arm, move to the center of thescissor arm and rotate down to a verticalposition.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
4 Tag and disconnect the wiring from the solenoidvalve at the barrel end of the lift cylinder.
5 Before serial number 40207: Tag anddisconnect the manual lowering cable from thesolenoid.
During assembly, the manualplatform lowering cable needs tobe properly adjusted. See 6-1,How to Adjust the Manual PlatformLowering Cable.
6 Tag, disconnect and plug the hydraulic hosefrom the lift cylinder. Cap the fitting on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
7 Attach a strap from an overhead crane orsimilar lifting device to the rod end of the liftcylinder for support.
8 Remove the lift cylinder rod-end pivot pinretaining fastener. Use a soft metal drift toremove the pin.
Crushing hazard. The lift cylinderwill fall if not properly supported.
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Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 33
SCISSOR COMPONENTS
9 Lower the cylinder onto the number 1 centerpivot pin.
10 Support and secure the entry ladder to anappropriate lifting device. Remove the entryladder mounting fasteners. Remove the entryladder from the machine.
Crushing hazard. The entry laddercould become unbalanced and fallif not properly supported andsecured to the lifting device whenremoved from the machine.
11 Remove the lift cylinder barrel-end pivot pinretaining fastener. Use a soft metal drift toremove the pin.
Crushing hazard. The lift cylinderwill fall if not properly supported.
12 Carefully pull the lift cylinder out the non-steerend of the machine through the scissor arms.
Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported whenremoved from the machine.
Component damage hazard. Becareful not to damage the valve orfittings on the cylinder whileremoving it from the machine.
GS-3268 RT:
Bodily injury hazard. Thisprocedure requires specific repairskills, lifting equipment and asuitable workshop. Attempting thisprocedure without these skills andtools could result in death orserious injury and significantcomponent damage. Dealerservice is strongly recommended.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
1 Start the engine and raise the platformapproximately 10 feet / 3 m.
2 Lift the safety arm, move to the center of thescissor arm and rotate down to a verticalposition.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
4 Tag and disconnect the wiring from the solenoidvalve at the barrel end of the lift cylinder.
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SCISSOR COMPONENTS
5 Tag, disconnect and plug the hydraulic hosefrom the lift cylinder. Cap the fitting on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
6 Attach a lifting strap from an overhead crane orsimilar lifting device to the rod end of the liftcylinder for support.
7 Remove the external snap ring from the liftcylinder rod-end pivot pin. Use a soft metal driftto remove the pin.
Crushing hazard. The lift cylinderwill fall if not properly supported.
8 Lower the cylinder to a horizontal position.
If removing the upper lift cylinder, disregardstep 9.
9 To remove the lower cylinder, support andsecure the entry ladder to an appropriate liftingdevice. Remove the entry ladder mountingfasteners. Remove the entry ladder from themachine.
Crushing hazard. The entry laddercould become unbalanced and fallif not properly supported andsecured to the lifting device whenremoved from the machine.
10 Support and secure the lift cylinder to anappropriate lifting device.
11 Remove the external snap ring from the liftcylinder barrel-end pivot pin. Use a soft metaldrift to remove the pin.
Crushing hazard. The lift cylinderwill fall if not properly supported.
12 Carefully pull the lift cylinder out the non-steerend of the machine through the scissor arms.
Crushing hazard. The lift cylindercould become unbalanced and fallif not properly supported whenremoved from the machine.
Component damage hazard. Becareful not to damage the valve orfittings on the cylinder whileremoving it from the machine.
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Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 35
Kubota D905 Engine
4-1Timing Adjustment
Complete information to perform this procedure isavailable in the Kubota D905 Workshop Manual(Kubota part number 97897-00870).
Kubota D905 Workshop ManualGenie part number 52229
4-3Engine RPM
How to Adjust the RPM1 Start the engine from the ground controls.
2 Hold the start toggle switch to the start positionand check the engine RPM on the diagnosticdisplay. Refer to Section 2, Specifications.Proceed to step 4 if the low idle is correct.
3 To correct the low idle speed, loosen the locknut, then turn the low idle adjustment screwclockwise to increase the rpm orcounterclockwise to decrease the rpm. Tightenthe lock nut and recheck the rpm.
4-2Glow Plugs
How to Check the Glow PlugsPerform this procedure with theengine turned off.
1 Connect the leads from an ohmmeter betweenthe far left glow plug and ground.
Result: The resistance should be approximately1Ω.
2 If the ohm reading is different than 1Ω, removethe wire and connector plate from the threeindividual glow plugs. Then, one glow plug at atime, measure the resistance between the glowplug and ground.
Result: The resistance should be approximately1.8Ω for each individual glow plug.
3 Install the connector plate and wires to all threeglow plugs.
4 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition.
5 Connect the red positive (+) lead from a voltmeter to the number three glow plug. Connectthe black negative (-) lead to ground.
6 Hold the glow plug switch in the on position.
Result: The volt meter should read 12V DC ormore.
a high idle solenoidb low idle adjustment screwc lock nutd 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 positionand check the engine RPM on the diagnosticdisplay. Refer to Section 2, Specifications.
6 To correct the high idle speed, loosen the locknut on the solenoid, then turn the solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten the locknut and recheck the rpm.
ba
d c
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4 - 36 GS-2668 RT • GS-3268 RT Part No. 52302
4-4Flex Plate
The flex plate couples the engine to the pump. Theflex plate is bolted to the engine flywheel and has asplined cut-out in the center to engage the pumpcoupler.
How to Remove the Flex Plate1 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 toengine fasteners.
3 Carefully pull the pump assembly away from theengine and secure it from moving.
Component damage hazard.Hoses can be damaged if they arekinked or pinched.
4 Remove the flex plate mounting fasteners.Remove the flex plate from the flywheel.
How to Install the Flex Plate1 Install the flex plate onto the flywheel with the
raised spline toward the pump.
Install the coupler onto the pumpshaft with the set screw towardsthe pump. Leave a1/32 inch / 0.8 mm gap betweenthe coupler and pump end plate.Apply Loctite® removable threadlocker to the coupler set screwand torque the set screw to65-70 ft-lbs / 88-95 Nm.
2 Apply Loctite® removable thread locker to theflex plate mounting fasteners. Torque the flexplate mounting fasteners to 36 ft-lbs / 49 Nm.
Component damage hazard. Donot force the drive pump duringinstallation or the flex plate splinesmay become damaged.
a b c d e
f
KUBOTA D905 ENGINE
a pumpb pump shaftc pump couplerd flex platee flywheelf 1/32 inch / 0.8 mm gap
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Section 4 • Repair ProceduresMarch 2005
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Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 37
KUBOTA D905 ENGINE
4-5Coolant Temperature and OilPressure Switches
The engine coolant temperature switch is anormally open switch. The switch contacts close atapproximately 225°F / 107°C. If the coolanttemperature rises above the switch point, theswitch contacts close and the engine will shut off toprevent damage. The engine will not start until thetemperature drops below the switch point. An over-temperature indicator light at the ground controlsshould turn on when the switch closes.
The engine oil pressure switch is a normally closedswitch. The switch contacts open at approximately7 psi / 0.48 bar. If the oil pressure drops below theswitch point, the contacts open and the engine willshut off to prevent damage. A low oil pressureindicator light at the ground controls should turn onwhen the switch opens.
How to Replace the CoolantTemperature and Oil PressureSwitches
Perform this procedure with theengine off.
1 Open the engine side cover and pull up on thelock pin on the engine pivot tray located underthe radiator. Swing the engine pivot tray out andaway from the machine to access bothswitches.
a coolant temperature switchb oil pressure switch
2 Tag and disconnect the wiring from the switch.Remove the switch from the engine.
Bodily injury hazard. Contact withhot engine fluids or componentsmay cause severe burns.
3 Install the new switch and tighten. Torqueto 8-18 ft-lbs / 11-24 Nm.
Always use pipe thread sealantwhen installing a new switch.
a b
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Section 4 • Repair Procedures March 2005
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4 - 38 GS-2668 RT • GS-3268 RT Part No. 52302
5-1Timing Adjustment -Gasoline/LPG Models
The ignition timing cannot beadjusted. The timing adjustmentscrew is factory sealed with atamper resistant cap installed bythe manufacturer. If service orrepair is needed, contact yourlocal Kubota dealer.
5-2Carburetor Adjustment -Gasoline/LPG Models
The carburetor cannot beadjusted. The carburetor mixturescrews are factory sealed withtamper resistant caps installed bythe manufacturer. If service orrepair is needed, contact yourlocal Kubota dealer.
Kubota DF750 / DF752 Engine
5-3Choke Adjustment -Gasoline/LPG Models
The choke is solenoid-operated and functions onlyin the gasoline mode. The choke will not operate inLPG mode.
5-4Flex Plate
See 4-4, Flex Plate.
5-5Coolant Temperature and OilPressure Switches
See 4-5, Coolant Temperature and Oil PressureSwitches.
Complete repair information for the Kubota DF752engine is available in theKubota DF752 Workshop Manual(Kubota part number 97897-02100).
Kubota DF752 Workshop ManualGenie part number 84249
Complete repair information for the Kubota DF750engine is available in theKubota DF750 Workshop Manual(Kubota part number 97897-00643).
Kubota DF750 Workshop ManualGenie part number 52492
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Section 4 • Repair ProceduresMarch 2005
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Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 39
KUBOTA DF750 / DF752 ENGINE
5-6Engine RPM
How to Adjust the RPMThe on-board self diagnosticsincorporate a built-in enginetachometer. The first two digits ofthe engine rpm are displayed onthe diagnostic display when thestart toggle switch is moved to thestart position with the enginerunning. Engine rpm equals thefirst two digits multiplied by 100.
Perform this procedure in gasolinemode with the engine at normaloperating temperature.
1 Start the engine from the ground controls.
2 Hold the start toggle switch to the start positionand check the engine RPM on the diagnosticdisplay. 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 idleadjustment screw on the carburetor clockwiseto increase rpm or counterclockwise todecrease rpm.
a b c d
a solenoid bootb threaded rodc yoke locknutd 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 positionand check the engine RPM on the diagnosticdisplay. Refer to Section 2, Specifications.
6 To correct the high idle speed, loosen the yokelock nut on the high idle solenoid, then turn thehigh idle adjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm.
Be sure the solenoid fully retractswhen activating high idle.
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Section 4 • Repair Procedures March 2005
REV A
4 - 40 GS-2668 RT • GS-3268 RT Part No. 52302
Perkins 403C-11 Engine
a edb c
6-1Engine RPM
How to Adjust the RPM1 Start the engine from the ground controls.
2 Hold the start toggle switch to the start positionand check the engine RPM on the diagnosticdisplay. Refer to Section 2, Specifications.Proceed to step 4 if the low idle is correct.
3 To correct the low idle speed, loosen thelocknut on the low idle adjustment screw. Turnthe low idle adjustment screw on the linkageclockwise to increase rpm or counterclockwiseto decrease rpm. Tighten the lock nut andrecheck the rpm. See the illustration.
4 Move the engine idle control switch to high idle(rabbit symbol) from the ground controls.
5 Hold the start toggle switch to the start positionand check the engine RPM on the diagnosticdisplay. Refer to Section 2, Specifications.
6 To correct the high idle speed, loosen the yokelock nut on the high idle solenoid, then turn thehigh idle adjustment nut and solenoid bootcounterclockwise to increase the rpm orclockwise to decrease the rpm. Tighten theyoke lock nut and recheck the rpm. See theillustration.
Be sure the solenoid fully retractswhen activating high idle.
6-2Timing Adjustment
Complete information to perform this procedure isavailable in the Perkins 403C-11 WorkshopManual (Perkins part number TPD1458).
Perkins 403C-11 Workshop ManualGenie part number 84817
a solenoidb yoke locknutc yoked low idle lock nute low idle adjustment screw
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Section 4 • Repair ProceduresMarch 2005
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 41
PERKINS 403C-11 ENGINE
6-3Flex Plate
See 4-4, Flex Plate.
6-4Coolant Temperature and OilPressure Switches
The engine coolant temperature switch is anormally open switch. The switch contacts close atapproximately 221°F / 105°C. If the coolanttemperature rises above the switch point, theswitch contacts close and the engine will shut off toprevent damage. The engine will not start until thetemperature drops below the switch point.
The engine oil pressure switch is a normally openswitch. The switch contacts close at approximately4.27 psi / 0.3 bar. If the oil pressure drops belowthe switch point, the contacts close and the enginewill shut off to prevent damage.
Before serial number GS6803-42382: A faultindicator light at the ground controls should turn onwhen either switch closes.After serial number GS6803-42381: A fault codewill be shown in the diagnostic display window atthe ground controls when either switch closes.
How to Replace the CoolantTemperature and Oil PressureSwitches
Perform this procedure with theengine off.
1 Open the engine side cover and pull up on thelock pin on the engine pivot tray located underthe radiator. Swing the engine pivot tray out andaway from the machine to access bothswitches.
2 Coolant temperature switch: Tag anddisconnect the wiring from the switch, locatedat the engine coolant outlet just above thealternator. Remove the switch from the engine.
Oil pressure switch: Tag and disconnect thewiring from the switch, located at the top of theengine just in front of the valve rocker cover.Remove the switch from the engine.
Bodily injury hazard. Contact withhot engine fluids or componentsmay cause severe burns.
3 Coolant temperature switch: Install the newswitch. Torque to 20 ft-lbs / 27 Nm.
Oil pressure switch: Install the new switch.Torque to 88 in-lbs / 10 Nm.
Always use pipe thread sealantwhen installing a new switch.
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Section 4 • Repair Procedures March 2005
REV B
4 - 42 GS-2668 RT • GS-3268 RT Part No. 52302
Ground Controls
7-1Auxiliary Platform Lowering
Auxiliary Platform Lowering,GS-2668 RT(before serial number 40207)The manual platform lowering system lowers theplatform in the event of a main power failure. Themanual platform lowering cable is attached to thebarrel end of the lift cylinder and is activated nextto the ground controls.
How to Adjust the ManualPlatform Lowering Cable1 Raise the platform approximately 10 feet / 3 m.
2 Lift the safety arm, move to the center of thescissor arm and rotate to a vertical position.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
4 Push the handle on the manual platformlowering cable all the way in.
5 Disconnect the cable mounting nut from thelowering valve at the barrel end of the liftcylinder.
6 Pull the cable tight and measure the distancebetween the end of the lowering cable and theend of the lowering valve.
Result: The measurement should be 3/16 to1/4 inch / 4.7 to 6.4 mm.
7 To adjust, loosen the upper lock nut on thecable mounting bracket. Turn the lower lock nutclockwise to decrease the distance orcounterclockwise to increase the distance.
8 Tighten the upper lock nut and repeat step 6 toconfirm the distance between the end of thelowering cable and the end of the loweringvalve.
9 Install the cable mounting nut onto the loweringvalve.
10 Raise the platform and rotate the safety arm tothe stowed position.
11 Pull the manual lowering handle at the groundcontrols 2 to 3 times to ensure it is functioningcorrectly.
AE
a
b
c
d
e
f
g
a manual lowering cable sheathb upper lock nutc cable mounting bracketd lower lock nute cable mounting nutf end of the lowering cableg manual lowering valve
(hydraulic schematic item AE)
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 43
GROUND CONTROLS
Auxiliary Platform Lowering,GS-3268 RT, andGS-2668 RT (after serialnumber 40206)In the event of a main power failure, activating thefunction enable and manual platform loweringbuttons at the ground controls will lower theplatform. There is no adjustment required.
Before serial number 41824, two 6V DC batterieswired in series supply power for the manualplatform lowering function. These batteries arelocated behind the ground control panel.
After serial number 41823, the auxiliary platformlowering circuit uses the main 12V battery for itspower source.
How to Replace a ManualPlatform Lowering Battery(before serial number 41824)1 Open the ground controls cover.
2 Remove the ground control panel fasteners andopen the panel.
3 Tag and disconnect the wires from the batteryto be removed.
4 Remove the battery from the machine.
5 Install the new battery and connect the wires.
6 Close the ground control panel and install thefasteners.
7 Close the ground controls cover.
7-2Function Speed Tuning(after serial number GS6803-42381)
All machine function speeds are determined by thepercentage of total ECM voltage output. Thespeeds of the following machine functions may beadjusted to compensate for wear in the hydraulicpump and drive motors.
· Stowed drive speed
· High torque drive speed
· Raised drive speed
· Platform lift speed
To adjust the function speeds on machines beforeserial number GS6803-42382, see 1-3,Function Speed Tuning (before serial numberGS6803-42382).
For further information or assistance, consult theGenie Industries Service Department.
Tip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingdrive speed greater thanspecifications could cause themachine to tip over resulting indeath or serious injury.
Tip-over hazard. This proceduremust only be performed by atrained service professional.Attempting this procedure withoutthe necessary skills will result indeath or serious injury.
How toDetermine the Revision Level1 Turn the key switch to ground controls and pull
out the red Emergency Stop buttons to the onposition at both platform and ground controls.
Result: The revision level of the ECM willappear in the LED display window.
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Section 4 • Repair Procedures March 2005
REV B
4 - 44 GS-2668 RT • GS-3268 RT Part No. 52302
How toAdjust the Stowed Drive Speed
Tip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingdrive speed greater thanspecifications could cause themachine to tip over resulting indeath or serious injury.
On machines with softwarerevision B1 or lower, stowed drivespeeds in forward and reverse aresimultaneously adjusted, resultingin both directions of traveloperating at the same speed.On machines with softwarerevision C0 or higher, the stowedforward drive speed and thestowed reverse drive speed maybe adjusted independent of oneanother. See 7-2, How toDetermine the Revision Level.
Models with software revision B1 or lower:
1 Pull out the red Emergency Stop button to theon position at the platform controls.
2 Push in the red Emergency Stop button to theoff position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll tomax high speed drive.
Result: MAX HIGH SPEED DRIVE is showing in thediagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button todecrease the drive speed or press the blueplatform up button to increase the drive speed.Refer to Section 2, Specifications.
The performance achieved shouldalways be within specifications.
9 Press the lift function enable button.
10 Push in the red Emergency Stop button to theoff position at the ground controls.
11 Check the stowed drive speed of the machine.Refer to the Maintenance procedure B-10, Testthe Drive Speed - Stowed Position.
b
c
d
a
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 45
Models with software revision C0 or higher:
1 Pull out the red Emergency Stop button to theon position at the platform controls.
2 Push in the red Emergency Stop button to theoff position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll tomax fwd high speed drive.
Result: MAX FWD HIGH SPEED DRIVE is showing inthe diagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button todecrease the drive speed or press the blueplatform up button to increase the drive speed.Refer to Section 2, Specifications.
The performance achieved shouldalways be within specifications.
9 Press the lift function enable button.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
b
c
d
a
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
10 Press the lift function enable button.
11 Use the yellow platform down arrow to scroll tomax rev high speed drive.
Result: MAX REV HIGH SPEED DRIVE is showing inthe diagnostic display window.
12 Press the lift function enable button.
13 Press the yellow platform down button todecrease the drive speed or press the blueplatform up button to increase the drive speed.Refer to Section 2, Specifications.
The performance achieved shouldalways be within specifications.
14 Press the lift function enable button.
15 Push in the red Emergency Stop button to theoff position at the ground controls.
16 Check the stowed drive speed of the machine.Refer to the Maintenance procedure B-10, Testthe Drive Speed - Stowed Position.
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
REV B
4 - 46 GS-2668 RT • GS-3268 RT Part No. 52302
How to Adjust theHigh Torque Drive Speed
Tip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingdrive speed greater thanspecifications could cause themachine to tip over resulting indeath or serious injury.
On machines with softwarerevision B1 or lower, high torquedrive speeds in forward andreverse are simultaneouslyadjusted, resulting in bothdirections of travel operating at thesame speed.On machines with softwarerevision C0 or higher, the hightorque forward drive speed andthe high torque reverse drivespeed may be adjustedindependent of one another. See7-2, How to Determine theRevision Level.
Models with software revision B1 or lower:
1 Pull out the red Emergency Stop button to theon position at the platform controls.
2 Push in the red Emergency Stop button to theoff position at the ground controls.
3 Turn the key switch to ground control.
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
4 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll tomax high torque drive.
Result: MAX HIGH TORQUE DRIVE is showing in thediagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button todecrease the drive speed or press the blueplatform up button to increase the drive speed.Refer to Section 2, Specifications.
The performance achieved shouldalways be within specifications.
9 Press the lift function enable button.
10 Push in the red Emergency Stop button to theoff position at the ground controls.
b
c
d
a
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 47
b
c
d
a
Models with software revision C0 or higher:
1 Pull out the red Emergency Stop button to theon position at the platform controls.
2 Push in the red Emergency Stop button to theoff position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll tomax fwd high torque drive.
Result: MAX FWD HIGH TORQUE DRIVE is showing inthe diagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button todecrease the drive speed or press the blueplatform up button to increase the drive speed.Refer to Section 2, Specifications.
The performance achieved shouldalways be within specifications.
9 Press the lift function enable button.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
10 Press the lift function enable button.
11 Use the yellow platform down arrow to scroll tomax rev high speed drive.
Result: MAX REV HIGH TORQUE DRIVE is showing inthe diagnostic display window.
12 Press the lift function enable button.
13 Press the yellow platform down button todecrease the drive speed or press the blueplatform up button to increase the drive speed.Refer to Section 2, Specifications.
The performance achieved shouldalways be within specifications.
14 Press the lift function enable button.
15 Push in the red Emergency Stop button to theoff position at the ground controls.
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
REV B
4 - 48 GS-2668 RT • GS-3268 RT Part No. 52302
How toAdjust the Raised Drive Speed
Tip-over hazard. Do not adjust thelift and/or drive speed higher thanspecified in this procedure. Settingdrive speed greater thanspecifications could cause themachine to tip over resulting indeath or serious injury.
On machines with softwarerevision B1 or lower, raised drivespeeds in forward and reverse aresimultaneously adjusted, resultingin both directions of traveloperating at the same speed.On machines with softwarerevision C0 or higher, the raisedforward drive speed and the raisedreverse drive speed may beadjusted independent of oneanother. See 7-2, How toDetermine the Revision Level.
Models with software revision B1 or lower:
1 Pull out the red Emergency Stop button to theon position at the platform controls.
2 Push in the red Emergency Stop button to theoff position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll toraised drive speed.
Result: MAX RAISED DRIVE SPEED is showing in thediagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button todecrease the raised drive speed or press theblue platform up button to increase the raiseddrive speed. Refer to Section 2, Specifications.
The performance achieved shouldalways be within specifications.
9 Press the lift function enable button.
10 Push in the red Emergency Stop button to theoff position at the ground controls.
11 Check the raised drive speed of the machine.Refer to the Maintenance procedure B-11, Testthe Drive Speed - Raised Position.
b
c
d
a
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 49
b
c
d
a
Models with software revision C0 or higher:
1 Pull out the red Emergency Stop button to theon position at the platform controls.
2 Push in the red Emergency Stop button to theoff position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll tomax fwd high torque drive.
Result: MAX FWD RAISED DRIVE SPEED is showing inthe diagnostic display window.
7 Press the lift function enable button.
8 Press the yellow platform down button todecrease the drive speed or press the blueplatform up button to increase the drive speed.Refer to Section 2, Specifications.
The performance achieved shouldalways be within specifications.
9 Press the lift function enable button.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
10 Press the lift function enable button.
11 Use the yellow platform down arrow to scroll tomax rev high speed drive.
Result: MAX REV RAISED DRIVE SPEED is showing inthe diagnostic display window.
12 Press the lift function enable button.
13 Press the yellow platform down button todecrease the drive speed or press the blueplatform up button to increase the drive speed.Refer to Section 2, Specifications.
The performance achieved shouldalways be within specifications.
14 Press the lift function enable button.
15 Push in the red Emergency Stop button to theoff position at the ground controls.
16 Check the raised drive speed of the machine.Refer to the Maintenance procedure B-11, Testthe Drive Speed - Raised Position.
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
REV B
4 - 50 GS-2668 RT • GS-3268 RT Part No. 52302
b
c
d
aHow toAdjust the Lift Speed1 Pull out the red Emergency Stop button to the
on position at the platform controls.
2 Push in the red Emergency Stop button to theoff position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window. The ECM is now inprogramming mode.
5 Press the lift function enable button.
6 Use the yellow platform down arrow to scroll tolift speed.
Result: MAX LIFT SPEED is showing in thediagnostic display window.
7 Press the lift function enable button.
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
8 Press the yellow platform down button todecrease the maximum lift speed or press theblue platform up button to increase themaximum lift speed. Refer to Section 2,Specifications.
The performance achieved shouldalways be within specifications.
9 Press the lift function enable button.
10 Push in the red Emergency Stop button to theoff position at the ground controls.
11 Check the lift speed of the machine. Refer toSection 2, Specifications.
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 51
b
c
d
a
7-3Software Configuration(after serial number GS6803-42381)
How to Configure the SoftwareThe Electronic Control Module (ECM) containsprogramming for all configurations of the GS-68.Models after serial number GS6803-42381 can beadjusted to a different configuration using thebuttons at the ground controls.
ANSI and CSA models:
1 Pull out the red Emergency Stop button to theon position at the platform controls.
2 Push in the red Emergency Stop button to theoff position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window.
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
Machine Option Definitions
Descent Delay: This option halts descent atapproximately 12 feet / 3.6 m. All controls mustbe released for 4 to 6 seconds before descentis re-enabled. Required for Europe.
Lift/Drive Cut Out: Lift and drive functions aredisabled when the down limit switch isactivated and the machine is on a slopeexceeding the rating on the serial plate.Activated for all machines.
Motion Alarm: The motion alarm will soundwhen activating a function.
Motion Beacons: The flashing beaconsoperate only when activating a function.
Overload: This cuts out all functions when theplatform overload pressure switch is tripped.The red Emergency Stop button must becycled before any function can be resumed.Required for Europe.
Sim Operation: When enabled, this allowssome machine functions to be activatedsimultaneously. Required to be disabled forEuropean models.
Beacons: When installed on the machine, theflashing beacons operate continuously whenthe key switch is turned to ground or platformcontrols and both red Emergency Stop buttonsare pulled out to the on position.
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
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4 - 52 GS-2668 RT • GS-3268 RT Part No. 52302
5 Use the yellow platform down arrow to scroll toselect options.
Result: SELECT OPTIONS is showing in thediagnostic display window. The ECM is now inprogramming mode.
6 Press the lift function enable button.
Result: DESCENT DELAY is showing in thediagnostic display window. Press the liftfunction enable button to activate or deactivatethe descent delay option OR use the yellowplatform down arrow to scroll to lift/drive cutout.
Result: LFT/DRV CUTOUT ON is showing in thediagnostic display window.
Result: LFT/DRV CUTOUT OFF is showing in thediagnostic display window. Press the liftfunction enable button to activate the lift/drivecutout option.
The lift/drive cutout option shouldbe activated or in the ON position.
7 Use the yellow platform down arrow to scroll tomotion alarm.
Result: MOTION ALARM is showing in thediagnostic display window.
8 Press the lift function enable button to activateor deactivate the motion alarm option OR usethe yellow platform down arrow to scroll tomotion beacons.
Result: MOTION BEACONS is showing in thediagnostic display window.
9 Press the lift function enable button to activateor deactivate the motion beacons option.
For this option to functioncorrectly, the machine must beequipped with flashing beacons.
10 Models with platform overload (option): Usethe yellow platform down arrow to scroll tooverload.
Result: OVERLOAD ON is showing in the diagnosticdisplay window.
Result: OVERLOAD OFF is showing in thediagnostic display window. Press the liftfunction enable button to activate the overloadoption.
11 Use the yellow platform down arrow to scroll tosim operation.
Result: SIM OPERATION ON is showing in thediagnostic display window.
Result: SIM OPERATION OFF is showing in thediagnostic display window. Press the liftfunction enable button to activate the simoperation option.
For all models except CE, the simoperation option should beactivated or in the ON position.
12 Use the yellow platform down arrow to scroll toreturn to the main menu.
Result: RETURN TO MAIN MENU is showing in thediagnostic display window.
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 53
13 Press the lift function enable button.
Result: SELECT OPTIONS is showing in thediagnostic display window.
14 Push in the red Emergency Stop button to theoff position at the ground controls.
CE models:
1 Pull out the red Emergency Stop button to theon position at the platform controls.
2 Push in the red Emergency Stop button to theoff position at the ground controls.
3 Turn the key switch to ground control.
4 Press and hold both the blue platform up andyellow platform down buttons. Pull out the redEmergency Stop button to the on position at theground controls.
Result: TUNE SPEEDS is showing in the diagnosticdisplay window.
5 Use the yellow platform down arrow to scroll toselect options.
Result: SELECT OPTIONS is showing in thediagnostic display window. The ECM is now inprogramming mode.
6 Press the lift function enable button.
Result: DESCENT DELAY ON is showing in thediagnostic display window.
Result: DESCENT DELAY OFF is showing in thediagnostic display window. Press the liftfunction enable button to activate the descentdelay option.
For CE models, the descent delayoption should be activated or inthe ON position.
7 Use the yellow platform down arrow to scroll tolift/drive cutout.
Result: LFT/DRV CUTOUT ON is showing in thediagnostic display window.
Result: LFT/DRV CUTOUT OFF is showing in thediagnostic display window. Press the liftfunction enable button to activate the lift/drivecutout option.
The lift/drive cutout option shouldbe activated or in the ON position.
8 Use the yellow platform down arrow to scroll tomotion alarm.
Result: MOTION ALARM is showing in thediagnostic display window.
b
c
d
a
a diagnostic displayb blue platform up buttonc lift function enable buttond yellow platform down button
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
REV B
4 - 54 GS-2668 RT • GS-3268 RT Part No. 52302
9 Press the lift function enable button to activateor deactivate the motion alarm option OR usethe yellow platform down arrow to scroll tomotion beacons.
Result: MOTION BEACONS is showing in thediagnostic display window.
10 Press the lift function enable button to activateor deactivate the motion beacons option ORuse the yellow platform down arrow to scroll tooverload.
For this option to functioncorrectly, the machine must beequipped with flashing beacons.
Result: OVERLOAD ON is showing in the diagnosticdisplay window.
Result: OVERLOAD OFF is showing in thediagnostic display window. Press the liftfunction enable button to activate the overloadoption.
For CE models, the overloadoption should be activated or inthe ON position.
11 Use the yellow platform down arrow to scroll tosim operation.
Result: SIM OPERATION OFF is showing in thediagnostic display window.
Result: SIM OPERATION ON is showing in thediagnostic display window. Press the liftfunction enable button to deactivate the simoperation option.
For CE models, the sim operationoption should be deactivated or inthe OFF position.
12 Use the yellow platform down arrow to scroll toreturn to the main menu.
Result: RETURN TO MAIN MENU is showing in thediagnostic display window.
13 Press the lift function enable button.
Result: SELECT OPTIONS is showing in thediagnostic display window.
14 Push in the red Emergency Stop button to the
off position at the ground controls.
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 55
7-4Level Sensor -Models without Outriggers(before serial number 41754)
The Electronic Control Module (ECM) isprogrammed to deactivate the lift and drivefunctions and activate an alarm when a signal isreceived from the level sensor.
The tilt alarm sounds when the incline of thechassis exceeds 2° to the side, 3° to the front or 5°to the rear.
How to Install and Calibrate theLevel Sensor
Tip-over hazard. Failure to installor calibrate the level sensor asinstructed could result in themachine tipping over causingdeath or serious injury. Do notinstall or calibrate the level sensorother than specified in thisprocedure.
Perform this procedure with themachine on a firm, level surfacethat is free of obstructions. Use adigital level to confirm.
1 Remove the platform controls from the platform.
2 Block the wheels at the non-steer end of themachine.
3 Center a lifting jack under the drive chassis atthe steer end of the machine.
4 Raise the machine approximately4 inches / 10 cm.
5 Place a 1.27 x 10 x 10 inch / 3.23 x 25 x 25 cmthick steel block under both wheels at the steerend of the machine.
6 Lower the machine onto the blocks.
7 Turn the key switch to platform control and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.
8 Before serial number 41137: Raise theplatform at least 12 feet / 3.6 m.
Result - ANSI and CSA models: The tilt alarmwill sound at 180 beeps per minute.
Result - CE and Australian models: The drivefunction and the lift function will not operate andthe tilt alarm will sound at 180 beeps perminute.
After serial number 41136: Raise the platformat least 12 feet / 3.6 m.
Result - The drive function and the lift functionwill not operate and the tilt alarm will sound at180 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 theoff position at the platform controls.
Before serial number 41200:
10 Remove the ground control panel retainingfasteners and open the panel. Locate the levelsensor behind the ground control panel.
After serial number 41199:
11 Lift the safety arm, move to the center of thescissor arm and rotate to a vertical position.
12 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
REV B
4 - 56 GS-2668 RT • GS-3268 RT Part No. 52302
GROUND CONTROLS
13 Locate the level sensor enclosure on thechassis under the limit switches at the steerend of the machine. Remove the enclosurecover retaining fasteners and the cover.
Level sensor (after serial number 41199)
a level sensorb max height limit switch (CE models)c down limit switchd load sense delay limit switch (CE models)
All models:
14 Tag and disconnect the wire harness from thelevel sensor.
15 Remove the fasteners securing the level sensorto the chassis. Remove the level sensor fromthe machine.
16 Install the new level sensor onto the machinewith the "Y" on the level sensor base closest tothe steer end of the machine. Install and tightenthe level sensor retaining fasteners.
Tip-over hazard. The tilt levelsensor must be installed with the"Y" on the level sensor baseclosest to the steer end of themachine. Failure to install the tiltlevel sensor as instructed willcause the machine to tip overresulting in death or serious injury.
Level sensor - models without outriggers
a chassisb level sensorc "X" indicatord "Y" indicator
XY
MODELS
OUTRIGGERS
WITHOUT
b
d
c
a
BEFORESERIAL NUMBER
41200
AFTERSERIAL NUMBER
41199
MODELS
OUTRIGGERS
WITHOUT
d
c
b
XY
a
a dcb
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 57
GROUND CONTROLS
17 Connect the wire harness to the level sensor.
18 Pull out the red Emergency Stop button to theon position at the platform controls.
19 Tighten the level sensor adjusting fastenersuntil the bubble in the top of the level sensor iscentered in the circles.
Be sure there are threads showingthrough the top of the adjustingfasteners.
Result: The tilt sensor alarm should not sound.
20 After serial number 41199: Raise the platformand rotate the safety arm to the stowedposition.
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 thenon-steer end of the machine.
26 Block the wheels at the steer end of themachine.
27 Center a lifting jack under the drive chassis atthe non-steer end of the machine.
28 Raise the machine approximately12 inches / 0.3 m.
29 Place a 6.64 x 10 x 10 inch / 16.87 x 25 x 25 cmthick steel block under both wheels at thenon-steer end of the machine.
30 Lower the machine onto the blocks.
31 Before serial number 41137: Raise theplatform at least 12 feet / 3.6 m.
Result - ANSI and CSA models: The tilt alarmwill sound at 180 beeps per minute.
Result - CE and Australian models: The drivefunction and the lift function will not operate andthe tilt alarm will sound at 180 beeps perminute.
Result: If the tilt sensor alarm does not sound,adjust the tilt level sensor until the alarm justbegins to sound OR the down limit switch mayneed to be adjusted.
After serial number 41136: Raise the platformat least 12 feet / 3.6 m.
Result - The drive function and the lift functionwill not operate and the tilt alarm will sound at180 beeps per minute.
Result: If the tilt sensor alarm does not sound,adjust the tilt level sensor until the alarm justbegins to sound OR the down limit switch mayneed 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 steerend of the machine.
37 Center a lifting jack under the drive chassis atthe ground controls side of the machine.
38 Raise the machine approximately4 inches / 10 cm.
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Section 4 • Repair Procedures March 2005
REV B
4 - 58 GS-2668 RT • GS-3268 RT Part No. 52302
39 Models with RT tires: Place a1.85 x 10 x 10 inch / 4.7 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.Models with non-marking tires: Place a1.94 x 10 x 10 inch / 4.93 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.Models with industrial tires: Place a1.95 x 10 x 10 inch / 4.95 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.
40 Lower the machine onto the blocks.
41 Before serial number 41137: Raise theplatform at least 12 feet / 3.6 m.
Result: The tilt alarm does not sound and allfunctions will operate. Proceed to step 43.
Result - ANSI and CSA models: The tilt alarmsounds at 180 beeps per minute. Proceed tostep 42.
Result - CE and Australian models: The drivefunction and the lift function will not operate andthe tilt alarm sounds at 180 beeps per minute.Proceed to step 42.
After serial number 41136: Raise the platformat least 12 feet / 3.6 m.
Result: The tilt alarm does not sound and allfunctions will operate. Proceed to step 43.
Result - The drive function and the lift functionwill not operate and the tilt alarm sounds at 180beeps per minute. Proceed to step 42.
42 Turn the level sensor adjusting nuts just untilthe 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 atthe engine side of the machine.
48 Raise the machine approximately4 inches / 10 cm.
49 Models with RT tires: Place a2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.All other models: Place a2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.
50 Lower the machine onto the blocks.
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 59
51 Before serial number 41137: Raise theplatform at least 12 feet / 3.6 m.
Result - ANSI and CSA models: The tilt alarmwill sound at 180 beeps per minute.
Result - CE and Australian models: The drivefunction and the lift function will not operate andthe tilt alarm will sound at 180 beeps perminute.
Result: If the tilt sensor alarm does not sound,adjust the tilt level sensor until the alarm justbegins to sound OR the down limit switch mayneed to be adjusted.
After serial number 41136: Raise the platformat least 12 feet / 3.6 m.
Result - The drive function and the lift functionwill not operate and the tilt alarm will sound at180 beeps per minute.
Result: If the tilt sensor alarm does not sound,adjust the tilt level sensor until the alarm justbegins to sound OR the down limit switch mayneed to be adjusted.
52 Lower the platform to the stowed position.
53 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols.
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 groundcontrol panel. Install and securely tighten theretaining fasteners. Do not over tighten.
After serial number 41199: Install the coveronto the level sensor enclosure. Install andsecurely tighten the retaining fasteners. Do notover tighten.
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
REV B
4 - 60 GS-2668 RT • GS-3268 RT Part No. 52302
7-5Level Sensor -Models without Outriggers(after serial number 41753)
The Electronic Control Module (ECM) isprogrammed to deactivate the lift and drivefunctions and activate an alarm when a signal isreceived from the level sensor.
The tilt alarm sounds when the incline of thechassis exceeds 2° to the side and 3° to the frontor rear.
How to Install and Calibrate theLevel Sensor
Tip-over hazard. Failure to installor calibrate the level sensor asinstructed could result in themachine tipping over causingdeath or serious injury. Do notinstall or calibrate the level sensorother than specified in thisprocedure.
Perform this procedure with themachine on a firm, level surfacethat is free of obstructions. Use adigital level to confirm.
1 Remove the platform controls from the platform.
If you are not installing a new level sensor,proceed to step 13.
2 Raise the platform approximately 10 feet / 3 m.
3 Lift the safety arm, move to the center of thescissor arm and rotate to a vertical position.
GROUND CONTROLS
4 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
5 Locate the level sensor enclosure on thechassis under the limit switches at the steerend of the machine. Remove the enclosurecover retaining fasteners and the cover.
Level sensor (after serial number 41199)
a level sensorb max height limit switch (CE models)c down limit switchd load sense delay limit switch (CE models)
a dcb
6 Tag and disconnect the wire harness from thelevel sensor.
7 Remove the fasteners securing the level sensorto the chassis. Remove the level sensor fromthe machine.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 61
Level sensor - models without outriggers
a chassisb level sensorc "X" indicatord "Y" indicator
16 Models with RT tires: Place a1.85 x 10 x 10 inch / 4.7 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.Models with non-marking tires: Place a1.94 x 10 x 10 inch / 4.93 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.
17 Lower the machine onto the blocks.
8 Install the new level sensor onto the machinewith the "Y" on the level sensor base closest tothe steer end of the machine. Install and tightenthe level sensor retaining fasteners.
Tip-over hazard. The tilt levelsensor must be installed with the"Y" on the level sensor baseclosest to the steer end of themachine. Failure to install the tiltlevel sensor as instructed willcause the machine to tip overresulting in death or serious injury.
9 Connect the wire harness to the level sensor.
10 Turn the key switch to platform control and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.
11 Tighten the level sensor adjusting fastenersuntil the bubble in the top of the level sensor iscentered in the circles.
Be sure there are threads showingthrough the top of the adjustingfasteners.
Result: The tilt sensor alarm should not sound.
12 Raise the platform and rotate the safety arm tothe stowed position.
13 Lower the platform to the stowed position.
14 Center a lifting jack under the drive chassis atthe ground controls side of the machine.
15 Raise the machine approximately4 inches / 10 cm.
GROUND CONTROLS
MODELS
OUTRIGGERS
WITHOUT
d
c
b
XY
a
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Section 4 • Repair Procedures March 2005
REV B
4 - 62 GS-2668 RT • GS-3268 RT Part No. 52302
18 Raise the platform at least 12 feet / 3.6 m.
Result: The tilt alarm does not sound and allfunctions will operate. Proceed to step 20.
Result - The drive function and the lift functionwill not operate and the tilt alarm will sound at180 beeps per minute. Proceed to step 19.
19 Turn the level sensor adjusting nuts just untilthe level sensor alarm does not sound.
20 Lower the platform to the stowed position.
21 Raise the machine slightly.
22 Remove the blocks from under both wheels.
23 Lower the machine and remove the jack.
24 Center a lifting jack under the drive chassis atthe engine side of the machine.
25 Raise the machine approximately4 inches / 10 cm.
26 Models with RT tires: Place a2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.Models with non-marking tires: Place a2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.
27 Lower the machine onto the blocks.
28 Raise the platform at least 12 feet / 3.6 m.
Result - The drive function and the lift functionwill not operate and the tilt alarm will sound at180 beeps per minute.
Result: If the tilt sensor alarm does not sound,adjust the tilt level sensor until the alarm justbegins to sound OR the down limit switch mayneed to be adjusted.
29 Lower the platform to the stowed position.
30 Push in the red Emergency Stop button to theoff position at both the ground and platformcontrols.
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 sensorenclosure. Install and securely tighten theretaining fasteners. Do not over tighten.
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 63
7-6Level Sensor -Models with Outriggers
The Electronic Control Module (ECM) isprogrammed to deactivate the lift and drivefunctions and activate an alarm when a signal isreceived from the level sensor.
When the outriggers are stowed, the tilt alarmsounds when the incline of the chassis exceeds 2°to the side.
When the outriggers are deployed, the tilt alarmsounds when the incline of the chassis exceeds0.8° to the side.
At all times, the tilt alarm sounds when the inclineof the chassis exceeds 3° to the front or rear.
How to Install and Calibrate theLevel Sensor
Tip-over hazard. Failure to installor calibrate the level sensor asinstructed could result in themachine tipping over causingdeath or serious injury. Do notinstall or calibrate the level sensorother than specified in thisprocedure.
Perform this procedure with themachine on a firm, level surfacethat is free of obstructions. Use adigital level to confirm.
1 Remove the platform controls from the platform.
If you are not installing a new level sensor,proceed to step 8.
2 Before serial number 41200: Remove theground control panel retaining fasteners andopen the panel. Locate the level sensor behindthe ground control panel.
After serial number 41199:
3 Raise the platform approximately 10 feet / 3 m.
4 Lift the safety arm, move to the center of thescissor arm and rotate to a vertical position.
5 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
6 Locate the level sensor enclosure on thechassis under the limit switches at the steerend of the machine. Remove the enclosurecover retaining fasteners and the cover.
Level sensor (after serial number 41199)
a level sensorb max height limit switch (CE models)c down limit switchd load sense delay limit switch (CE models)
cb da
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
REV B
4 - 64 GS-2668 RT • GS-3268 RT Part No. 52302
Install the level sensor:
7 Tag and disconnect the wire harness from thelevel sensor.
8 Remove the fasteners securing the level sensorto the chassis. Remove the level sensor fromthe machine.
9 Install the new level sensor onto the machinewith the "X" on the level sensor base closest tothe steer end of the machine. Install and tightenthe level sensor retaining fasteners.
Tip-over hazard. The tilt levelsensor must be installed with the"X" on the level sensor baseclosest to the steer end of themachine. Failure to install the tiltlevel sensor as instructed couldresult in the machine tipping overcausing death or serious injury.
10 Connect the wire harness to the level sensor.
11 Turn the key switch to platform control and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.
12 Set a multimeter to read DC voltage.
Adjust the side-to-side axis:
13 Without disconnecting the wire harness fromthe level sensor, connect the negative lead ofthe multimeter to the black wire at the levelsensor.
14 Without disconnecting the wire harness fromthe level sensor, connect the positive lead ofthe multimeter to the yellow wire at the levelsensor.
Level sensor - models without outriggers
a chassisb level sensorc "Y" indicatord "X" indicator
Y
X
MODELS
OUTRIGGERS
WITH
b
a
c
d
BEFORESERIAL NUMBER
41200
AFTERSERIAL NUMBER
41199
MODELS
OUTRIGGERS
WITHb
d
caX
Y
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 65
15 Adjust the "Y" axis (side-to-side) to 2.5V DC.Tap the top of the level sensor lightly withfingers after each turn of an adjusting nut.
Tip-over hazard. Do not adjust thepotentiometers on the bottom ofthe level sensor or calibrate thelevel sensor other than specified inthis procedure. Failure to calibratethe tilt level sensor as instructedwill cause the machine to tip overresulting in death or serious injury.
Be sure there are threads showingthrough the top of each adjustingnut.
16 Disconnect the positive lead.
Adjust the front-to-back axis:
17 Without disconnecting the wire harness fromthe level sensor, connect the positive lead ofthe multimeter to the blue wire at the levelsensor.
18 Adjust the "X" axis (front-to-back) to 2.43V DC.Tap the top of the level sensor lightly withfingers after each turn of an adjusting nut.
Tip-over hazard. Do not adjust thepotentiometers on the bottom ofthe level sensor or calibrate thelevel sensor other than specified inthis procedure. Failure to calibratethe tilt level sensor as instructedwill cause the machine to tip overresulting in death or serious injury.
Be sure there are threads showingthrough the top of each adjustingnut.
19 Disconnect the positive and negative leads.
20 Apply Sentry Seal to the adjusting nuts.
21 Push in the red Emergency Stop button to theoff position at the platform controls.
22 Before serial number GS6803-42382: Pressand hold the outrigger enable button and pressand hold the auto level button and pull out thered Emergency Stop button to the on position atthe platform controls. Continue to hold theoutrigger enable button and the auto levelbutton for approximately 3 seconds or until abeep is heard. Release the buttons.After serial number GS6803-42381: Pressand hold the auto level button and press andhold the left front outrigger button. Pull out thered Emergency Stop button to the on position atthe platform controls. Continue to hold the autolevel button and left front outrigger button forapproximately 3 seconds or until a beep isheard. Release the buttons.
23 Push in the red Emergency Stop button to theoff position at the platform controls.
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
REV B
4 - 66 GS-2668 RT • GS-3268 RT Part No. 52302
Confirm the side-to-side level sensor setting:
24 Center a lifting jack under the drive chassis atthe ground control side of the machine.
25 Raise the machine approximately6 inches / 15 cm.
26 Models with RT tires: Place a2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.All other models: Place a2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.
27 Lower the machine onto the blocks.
28 Pull out the red Emergency Stop button to theon position at platform controls. Start theengine.
29 Raise the platform at least 12 feet / 3.6 m.
Result: The platform stops raising and the tiltalarm will sound at 180 beeps per minute.
Result: The platform does not stop raising andthe tilt alarm does not sound. The level sensormust be replaced. Repeat this procedurebeginning with step 2.
For reference only, the output ofthe level sensor should beapproximately 1.7V DC. Toconfirm, connect the positive leadof a multimeter to the yellow wireat the level sensor, and thenegative lead to the black wire.
30 Raise the machine slightly.
31 Remove the blocks from under both wheels.
32 Lower the machine and remove the jack.
33 Center a lifting jack under the drive chassis atthe tank side of the machine.
34 Raise the machine approximately6 inches / 15 cm.
35 Models with RT tires: Place a2.15 x 10 x 10 inch / 5.46 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.All other models: Place a2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm thicksteel block under both wheels at the groundcontrols side of the machine.
36 Lower the machine onto the blocks.
37 Raise the platform at least 12 feet / 3.6 m.
Result: The platform stops raising and the tiltalarm will sound at 180 beeps per minute.
Result: The platform does not stop raising andthe tilt alarm does not sound. The level sensormust be replaced. Repeat this procedurebeginning with step 2.
For reference only, the output ofthe level sensor should beapproximately 3.3V DC. Toconfirm, connect the positive leadof a multimeter to the yellow wireat the level sensor, and thenegative 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 Lower the machine and remove the jack.
GROUND CONTROLS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 67
Confirm the front-to-back level sensor setting:
42 Center a lifting jack under the drive chassis atthe steer end of the machine.
43 Raise the machine approximately6 inches / 15 cm.
44 Place a 4.08 x 10 x 10 inch / 10.36 x 25 x 25 cmthick steel block under both wheels at the steerend of the machine.
45 Lower the machine onto the blocks.
46 Raise the platform at least 12 feet / 3.6 m.
Result: The platform stops raising and the tiltalarm will sound at 180 beeps per minute.
Result: The platform does not stop raising andthe tilt alarm does not sound. The level sensormust be replaced. Repeat this procedurebeginning with step 2.
For reference only, the output ofthe level sensor should beapproximately 1.5V DC. Toconfirm, connect the positive leadof a multimeter to the blue wire atthe level sensor, and the negativelead 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 atthe non-steer end of the machine.
52 Raise the machine approximately6 inches / 15 cm.
53 Place a 4.08 x 10 x 10 inch / 10.36 x 25 x 25 cmthick steel block under both wheels at thenon-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 tiltalarm will sound at 180 beeps per minute.
Result: The platform does not stop raising andthe tilt alarm does not sound. The level sensormust be replaced. Repeat this procedurebeginning with step 2.
For reference only, the output ofthe level sensor should beapproximately 3.4V DC. Toconfirm, connect the positive leadof a multimeter to the blue wire atthe level sensor, and the negativelead 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.
GROUND CONTROLS
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Section 4 • Repair Procedures March 2005
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4 - 68 GS-2668 RT • GS-3268 RT Part No. 52302
Hydraulic Pump
8-1Hydraulic Pump
The hydraulic pump is a 2-section, gear-typepump. Pump number 1 is the pump section whichis closer to the engine and pump number 2 is thepump section that is farther from the engine. Eachsection of the pump has its own relief valve in thefunction manifold.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
How to Test the Hydraulic Pump1 Tag, disconnect and plug the high pressure
hydraulic hoses from both sections of thehydraulic pump.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
2 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the high pressure port on each sectionof the pump.
3 Gasoline/LPG models: Disconnect the ignitioncoil wire from the center of the ignition coil.
Diesel models: Hold the manual fuel shutofflever clockwise in the closed position.
4 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.
5 Observe the pressure gauge while cranking theengine. Immediately stop if the pressurereaches or exceeds 3000 psi / 206 bar in eitherone of the gauges.
Result: If both of the pressure gauges read3000 psi / 206 bar, immediately stop. The pumpis good.
Result: If pressure fails to reach3000 psi / 206 bar in one or both sections of thepump, one of the pump sections or the pumpcoupling is bad and will need to be serviced orreplaced.
6 Remove the pressure gauges and connect thehydraulic hoses.
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Section 4 • Repair ProceduresMarch 2005
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 69
How to Remove theHydraulic Pump1 Tag, disconnect and plug the hydraulic hoses
on the pump.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
2 Remove the pump mounting bolts. Carefullyremove the pump.
After replacing the hydraulicpump, it is critical to return the liftspeed and raised drive speedsettings to original factoryspecifications. Refer toMaintenance Procedure B-11 Testthe Drive Speed - Raised Positionto check the speeds, and seeRepair Procedure 1-3 ControllerAdjustments to correct the raiseddrive speed percentage settings.
HYDRAULIC PUMP
How to Prime the PumpComponent damage hazard. Besure that the hydraulic tank shutoffvalves (if equipped) are in theopen position before priming thepump. The engine must not bestarted with the hydraulic tankshutoff valves in the closedposition or component damage willoccur.
1 Connect a 0 to 600 psi / 0 to 50 bar pressuregauge to either diagnostic test port on thefunction manifold.
2 Turn the key switch to ground controls and pullout the red Emergency Stop buttons to the onposition at both the ground and platformcontrols.
3 Gasoline/LPG models: Close the valve on theLPG tank, then disconnect the hose from thetank (if equipped). Move the fuel select toggleswitch at the ground controls to the LPGposition.
Diesel models: Disconnect the wiring from thefuel shutoff solenoid.
4 Crank the engine with the starter motor for15 seconds, wait 15 seconds, then crank theengine an additional 15 seconds or until thepressure reaches 300 psi / 20.7 bar.
5 Gasoline/LPG models: Connect the hose tothe LPG tank and open the valve (if equipped).Move the fuel select toggle switch at the groundcontrols to the gasoline position.Diesel models: Connect the wiring to the fuelshutoff solenoid.
6 Start the engine from the ground controls andcheck for hydraulic leaks.
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Section 4 • Repair Procedures March 2005
REV B
4 - 70 GS-2668 RT • GS-3268 RT Part No. 52302
9-1Function Manifold ComponentsThe function manifold is located inside the hydraulic tray.
Index SchematicNo. Description Item Function Torque
1 DO3 valve, 3 position 4 way ................ A ......... Controls flow to the steer endground controls side drive motorand the non-steer end engine sidedrive motor in forward and reverse .......30-35 in-lbs / 3-4 Nm
2 DO3 valve, 3 position 4 way ................ B ......... Controls flow to the steer endengine side drive motor andthe non-steer end groundcontrols side drive motor inforward and reverse ..............................30-35 in-lbs / 3-4 Nm
3 Check valve ......................................... C ......... Drive speed select circuit .................. 25-30 ft-lbs / 34-41 Nm
4 Check valve ......................................... D ......... Prevents engine from runningbackwards when on an inclineand reversing direction of travel ........ 25-30 ft-lbs / 34-41 Nm
5 Check valve ......................................... E ......... Steer circuit ....................................... 25-30 ft-lbs / 34-41 Nm
6 Check valve ......................................... F ......... Proportional circuit ............................ 25-30 ft-lbs / 34-41 Nm
7 Relief valve, 3500 psi / 241.3 bar ........G ......... Relief valve for numberone section of pump.......................... 15-25 ft-lbs / 34-41 Nm
8 Check valve ......................................... H ......... Proportional circuit ................................30-35 in-lbs / 3-4 Nm
9 Diagnostic nipple - Test port #1 ........... I ........... Testing
10 Diagnostic nipple - Test port #2 ........... J .......... Testing
11 Relief valve,GS-2668 RT, 3500 psi / 241.3 barGS-3268 RT, 2000 psi / 37.8 bar ........K ......... Platform up ........................................ 15-25 ft-lbs / 34-41 Nm
12 Check valve ........................................ L .......... Drive circuit anti-cavitation ................ 20-25 ft-lbs / 27-54 Nm
13 Shuttle valve ........................................ M ......... Brake circuit ...................................... 20-25 ft-lbs / 27-54 Nm
Manifolds
This list continues. Please turn the page.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 71
MANIFOLDS
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20 19
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1
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Y6AY5
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Section 4 • Repair Procedures March 2005
REV B
4 - 72 GS-2668 RT • GS-3268 RT Part No. 52302
Function Manifold Components, continued
Index SchematicNo. Description Item Function Torque
14 Check valve ......................................... N ......... Drive circuit anti-cavitation ................ 20-25 ft-lbs / 27-34 Nm
15 Relief valve, 3500 psi / 241.3 bar ........O ......... Relief valve for numbertwo section of pump ............................ 5-25 ft-lbs / 34-41 Nm
16 Solenoid valve, 2 position 4 way ......... P ......... Platform up ........................................ 25-30 ft-lbs / 34-41 Nm
17 Priority flow regulator,2 gpm / 7.6 L/min ................................. Q ......... Steer circuit ....................................... 25-30 ft-lbs / 34-41 Nm
18 Solenoid valve, 3 position 4 way ......... R ......... Steer left/right ...................................... 5-30 ft-lbs / 34-41 Nm
19 Orifice - plug, 0.035 in / 0.89 mm ........S ......... Brake circuit
20 Proportional solenoid valve N.O. ........T ......... Drive/lift circuit ................................... 25-30 ft-lbs / 34-41 Nm
21 Solenoid valve, 2 position 2 wayN.O. ..................................................... U ......... Brake circuit ...................................... 20-25 ft-lbs / 27-54 Nm
22 Relief valve, 1500 psi / 103.4 bar ........V ......... Steer left/right .................................... 25-30 ft-lbs / 34-41 Nm
23 Solenoid valve, 2 position 2 wayN.O. poppet ......................................... W ........ Drive speed select circuit .................. 25-30 ft-lbs / 34-41 Nm
24 Solenoid valve, 2 position 2 wayN.O. poppet ......................................... X ......... Drive speed select circuit .................. 25-30 ft-lbs / 34-41 Nm
25 Solenoid valve, 2 position 2 wayN.C. ..................................................... Y ......... Drive speed select circuit .................. 25-30 ft-lbs / 34-41 Nm
26 Check valve ......................................... Z ......... Prevents overflowing the drivemotors when in high drive speed ...... 20-25 ft-lbs / 27-54 Nm
27 Check valve ......................................... AA ....... Prevents engine from runningbackwards when on an inclineand reversing direction of travel ........ 25-30 ft-lbs / 34-41 Nm
MANIFOLDS
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 73
MANIFOLDS
C
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L
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Y3
Y1
Y8
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AB
1
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Y6AY5
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Section 4 • Repair Procedures March 2005
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4 - 74 GS-2668 RT • GS-3268 RT Part No. 52302
9-2Valve Adjustments -Function Manifold
How toAdjust the System Relief ValvesThe function manifold contains two system reliefvalves, one for each section of the pump.
Perform this procedure with themachine on level ground.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to test port #2 (item J) and test port #1(item I) on the function manifold.
2 Place wheel chocks in front of all four wheels.
3 Remove the platform controls from the platformand place the controls near the functionmanifold on the tank side of the machine.
4 Models without outriggers: Start the enginefrom platform controls and press the hightorque button (BN6).
Models with outriggers: Start the engine fromplatform controls and press the high torque/leftfront outrigger button (BN17).
5 Move the joystick full stroke in the forwarddirection. Note the pressure readings on bothpressure gauges. Refer to Section 2,Specifications.
6 Turn the engine off. Use a wrench to hold theP2 system relief valve (item O) or P1 systemrelief valve (item G) and remove the cap .
MANIFOLDS
a P1 system relief valveb test port #1c test port #2d P2 system relief valve
7 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.
Tip-over hazard. Failure to adjustthe relief valve as instructed willcause the machine to tip overresulting in death or serious injury.Do not adjust the relief valvehigher than specified.
8 Repeat steps 4 through 5 to confirm the reliefvalve pressures.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 75
How to Adjust the Steer ReliefValve
Perform this procedure with theplatform in the stowed position.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to test port #2 (item J) on the functionmanifold.
2 Turn the key switch to platform control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.
3 Start the engine from the platform controls.
4 Press and hold the function enable toggleswitch and hold the steer thumb rocker switchin the right direction. Allow the wheels tocompletely turn to the right, then continueholding the switch while observing the pressurereading on the pressure gauge. Note thepressure. Refer to Section 2, Specifications.
5 Turn the engine off. Use a wrench to hold thesteer relief valve and remove the cap (item V).
6 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.
Component damage hazard. Donot adjust the relief valve higherthan specified.
7 Repeat steps 3 through 4 to confirm the reliefvalve pressure.
MANIFOLDS
a test port #2b steer relief valve
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Section 4 • Repair Procedures March 2005
REV B
4 - 76 GS-2668 RT • GS-3268 RT Part No. 52302
How to Adjust the Platform UpRelief Valve
Be sure that the hydraulic oil levelis within the top 2 inches / 5 cm ofthe sight gauge.
1 Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to test port #1 (item I) on the functionmanifold.
2 Place the maximum rated load in the platform.Secure the load to the platform. Refer toSection 2, Specifications.
3 Turn the key switch to ground control and pullout the red Emergency Stop button to the onposition at both the ground and platformcontrols.
4 Start the engine from the ground controls.
5 Press and hold the function enable switch andhold the platform up/down toggle switch in theup direction. Allow the platform to raisecompletely, then continue holding the switchwhile observing the pressure reading on thepressure gauge. Note the pressure. Refer toSection 2, Specifications.
6 Turn the engine off. Hold the platform up reliefvalve with a wrench and remove the cap(item K).
7 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.
Tip-over hazard. Failure to adjustthe relief valve as instructed willcause the machine to tip overresulting in death or serious injury.Do not adjust the relief valvehigher than specified.
8 Repeat steps 4 through 5 to confirm the reliefvalve pressure.
MANIFOLDS
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b
a test port #1b platform up relief valve
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 77
MANIFOLDS
9-3Outrigger Manifold ComponentsThe outrigger manifold is located beneath the hose cover panel on top of the drive chassis
Index SchematicNo. Description Item Function Torque
1 Relief valve, 2000 psi / 137.8 bar ......... BA ......... Outrigger circuit ..................................... 20 ft-lbs / 27.1 Nm
2 Solenoid valve, 2 position 2 way .......... BB ......... Outrigger slow extend .............................. 25 ft-lbs / 34 Nm
3 Orifice - plug,0.063 inch / 1.6 mm .............................. BC ......... Outrigger retract
4 Solenoid valve, 3 position 4 way .......... BD ......... Outrigger extend/retract ........................... 25 ft-lbs / 34 Nm
5 Counterbalance valve(not used after serial number 40484) ... BE ......... Outrigger retract circuit .................. 30-35 ft-lbs / 41-47 Nm
BA
BB
BD
Y44
Y40
Y39
3
4
1
2BC
5
5
BE
BE
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Section 4 • Repair Procedures March 2005
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4 - 78 GS-2668 RT • GS-3268 RT Part No. 52302
MANIFOLDS
9-4Valve Adjustments -Outrigger Manifold
How to Adjust the OutriggerRelief Valve
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
Perform this procedure with themachine on a firm, level surface.
1 Disconnect the platform controls from the quickdisconnect plug at the bottom of the platform.Remove the platform controls from the platform.
Component damage hazard. Theplatform controls wiring can bedamaged if it is kinked or pinched.
2 Open the hydraulic tank cover at the groundcontrols side of the machine and disconnect theplatform controls harness at the quickdisconnect plug above the hydraulic tank.
3 Connect the platform controls to the quickdisconnect plug above the hydraulic tank.
4 Turn the key switch to platform control and pullout the red Emergency Stop buttons to the ON
position at both the ground and platformcontrols.
5 Start the engine and raise the platformapproximately 10 feet / 3 m.
6 Lift the safety arm, move to the center of thescissor arm and rotate down to a verticalposition.
7 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
8 Stop the engine.
9 Disconnect the hydraulic supply hose from theIN port of the outrigger manifold.
The IN port of the outriggermanifold is located next to theoutrigger extend/retract valve(item BD) and is labeled as IN.
10 Install a tee into the in port and install theoutrigger manifold supply hose into the tee.Connect a 0 to 5000 psi / 0 to 350 bar pressuregauge to the tee of the outrigger manifold.Torque to specification. Refer to Section 2,Specifications.
11 Start the engine from the platform controls.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 79
12 Push and hold the auto level button and activatethe outrigger extend/retract toggle switch in thedown direction and note the pressure readingon the pressure gauge. Refer to Section 2,Specifications.
13 Turn the engine off. Use a wrench to hold theoutrigger relief valve (item BA) and remove thecap.
14 Adjust the internal hex socket. Turn it clockwiseto increase the pressure or counterclockwise todecrease the pressure. Install the relief valvecap.
15 Repeat steps 11 through 12 to confirm the reliefvalve pressure.
16 Remove the pressure gauge and tee from themanifold and install the outrigger manifoldsupply line into the outrigger manifold. Torqueto specification. Refer to Section 2,Specifications.
17 Raise the platform and return the safety arm tothe stowed position.
18 Lower the platform the stowed position and turnthe machine off.
19 Disconnect the platform controls from the quickdisconnect plug above the hydraulic tank andconnect the platform controls harness to thequick disconnect plug above the hydraulic tank.
20 Install the platform controls into the platform andconnect the platform controls to the quickdisconnect plug at the bottom of the platform.
MANIFOLDS
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Section 4 • Repair Procedures March 2005
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4 - 80 GS-2668 RT • GS-3268 RT Part No. 52302
MANIFOLDS
9-5Generator Manifold ComponentsThe generator manifold is located above the function manifold.
Index SchematicNo. Description Item Function Torque
1 Solenoid valve, 2 position 3 way ......... AB .......... Generator on/off .................................. 25 ft-lbs / 34 Nm
2 Flow regulator, 4.3 gpm / 16.3 L/min ... AC .......... Generator speed ................................. 20 ft-lbs / 27.1 Nm
3 Relief valve, 3000 psi / 206.8 bar ........ AD .......... Generator circuit .................................. 20 ft-lbs / 27.1 Nm
AD
AC
AB1
2
3
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 81
MANIFOLDS
9-6Valve Adjustments -Generator Manifold
How to Adjust the GeneratorVoltage
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
Be sure that the hydraulic oil levelis within the top 2 inches / 5 cm ofthe sight gauge.
Perform this procedure with themachine on a firm, level surface.
1 Disconnect all electrical tools from the machine.
2 Start the engine from the platform controls.
3 Press the generator select switch.
Result: The generator should activate and theengine should go to high rpm.
4 Connect an electrical tool, which does not drawmore than 15A, to the electrical outlet at theplatform controls and run the tool at full speed.
5 Connect the positive and negative leads from amultimeter of sufficient capacity to the electricaloutlet at the generator.
Result: The reading on the multimeter should be112V to 118V AC.
Result: If the reading on the multimeter is not112V to 118V AC, proceed to step 6.
6 Turn the key switch to the off position.
7 Use a wrench to hold the generator flowregulator valve (item AC) and remove the cap.
8 Adjust the internal hex socket. Turn it clockwiseto increase the AC voltage or counterclockwiseto decrease the AC voltage. Install the flowregulator valve cap.
Component damage hazard.Failure to adjust the generator asinstructed may result in damage tothe generator or other electricalequipment. Do not adjust thegenerator to other than specified.
9 Repeat steps 2 through 5 to confirm thegenerator AC voltage.
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Section 4 • Repair Procedures March 2005
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4 - 82 GS-2668 RT • GS-3268 RT Part No. 52302
MANIFOLDS
9-7Valve Coils
How to Test a CoilA properly functioning coil provides anelectromotive force which operates the solenoidvalve. Critical to normal operation is continuitywithin the coil that provides this force field.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
Not all solenoid valve coils utilizean integrated diode; review theelectrical schematic for yourmachine to confirm. Refer toSection 7, Schematics.
1 Tag and disconnect the wire harness from thecoil to be tested.
2 Test the coil resistance.
Result: The resistance should be withinspecification, plus or minus 30%.
Result: If the resistance is not withinspecification, plus or minus 30%, replace thecoil.
Valve Coil Resistance Specifications
Description Specification
DO3 valve, 3 position 4 way 3.5 - 4.5Ω12V DC with diode (schematic items A and B)
Solenoid valve, 2 position 4 way 7 to 8Ω12V DC with diode (schematic item P)
Solenoid valve, 3 position 4 way 7 to 8Ω12V DC with diode (schematic item R)
Proportional valve, 4 to 6Ω12V DC (schematic item T)
Solenoid valve, 2 position 2 way 9 to 10Ω12V DC with diode (schematic items U, W, X and Y)
Solenoid valve, 2 position 3 way 5.5 to 6.5Ω12V DC (schematic item AB)
Solenoid valve, 2 position 2 way 8 to 10Ω12V DC with diode (schematic item AI)
Solenoid valve, 2 position 2 way 7 to 8Ω12V DC (schematic item BB)
Solenoid valve, 3 position 4 way 7 to 8Ω12V DC (schematic item BD)
Solenoid valve, 2 position 2 way 7.2 to 9.2Ω10V DC (schematic items CA, CB, CC and CD)
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 83
MANIFOLDS
How to Test a Coil DiodeGenie incorporates spike suppressing diodes inmany valve coils. Properly functioning coil diodesprotect the electrical circuit by suppressing voltagespikes. Voltage spikes naturally occur within afunction circuit following the interruption ofelectrical current to a coil. Faulty diodes can fail toprotect the electrical system, resulting in a trippedcircuit breaker or component damage.
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
1 Test the coil for resistance. See 9-3, How toTest a Coil.
2 Connect a 10 resistor to the negative terminalof a known good 9V DC battery. Connect theother end of the resistor to a terminal on thecoil.
The battery should read 9V DC ormore when measured across theterminals.
Resistor, 10Genie part number 27287
3 Set a multimeter to read DC current.
The multimeter, when set to readDC current, should be capable ofreading up to 800 mA.
a multimeterb 9V DC batteryc 10 resistord coil
Note: Dotted lines in illustration indicate areversed connection as specified in step 6
9VBATTERY
10
RESISTOR
MULTIMETER
COIL
+
-
+
-
d
b
b
a
c
c
4 Connect the negative lead to the other terminalon the coil.
If testing a single-terminal coil,connect the negative lead to theinternal metallic ring at either endof the coil.
5 Momentarily connect the positive lead from themultimeter to the positive terminal on the 9V DCbattery. Note the current reading.
6 At the battery or coil terminals, reverse theconnections. Note the current reading.
Result: Both current readings are greater than0 mA and are different by a minimum of 20%.The coil is good.
Result: If one or both of the current readings are0 mA, or if the two current readings do not differby a minimum of 20%, the coil and/or itsinternal diode are faulty and the coil should bereplaced.
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Section 4 • Repair Procedures March 2005
REV B
4 - 84 GS-2668 RT • GS-3268 RT Part No. 52302
Fuel and Hydraulic Tanks
10-1Fuel Tank
How to Remove the Fuel TankExplosion and fire hazard. Enginefuels are combustible. Remove thefuel tank in an open, well-ventilated area away from heaters,sparks, flames and lightedtobacco. Always have anapproved fire extinguisher withineasy reach.
Explosion and fire hazard. Whentransferring fuel, connect agrounding wire between themachine and pump or container.
Explosion and fire hazard. Neverdrain or store fuel in an opencontainer due to the possibility offire.
1 Remove the fuel filler cap from the tank.
2 Using an approved hand-operated pump, drainthe fuel tank into a suitable container. Seecapacity specifications.
Be sure to only use a handoperated pump suitable for usewith gasoline and/or diesel fuel.
3 Models with fuel shutoff valves: Close thefuel tank shutoff valves.
4 Tag, disconnect and plug the fuel supply andreturn hoses from the fuel tank.
5 Clean up any fuel that may have spilled.
6 Remove the fuel tank mounting fasteners.
7 Remove the fuel tank from the machine.
Component damage hazard. Thefuel tank is plastic and maybecome damaged if allowed to fall.
Component damage hazard.During installation, do notovertighten the fuel tank mountingfasteners. Torque the fuel tankmounting fasteners to54 in-lbs / 6.1 Nm.
Clean the fuel tank and inspectfor cracks or other damage beforeinstalling.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 85
FUEL AND HYDRAULIC TANKS
10-2Hydraulic Tank
The primary functions of the hydraulic tank are tocool, clean and deaerate the hydraulic fluid duringoperation. It utilizes internal suction strainers forthe pump supply lines and has an external returnline filter.
How to Remove theHydraulic Tank
Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
1 Raise the platform approximately 10 feet / 3 m.
2 Lift the safety arm, move it to the center of thescissor arm and rotate down to a verticalposition.
3 Lower the platform onto the safety arm.
Crushing hazard. Keep handsclear of the safety arm whenlowering the platform.
4 Remove the hose cover plate mountingfasteners. Remove the cover.
5 Close the two hydraulic shutoff valves locatedat the hydraulic tank.
Component damage hazard. Theengine must not be started withthe hydraulic tank shutoff valves inthe closed position or componentdamage will occur. If the tankvalves are closed, remove the keyfrom the key switch and tag themachine to inform personnel of thecondition.
6 Open the hydraulic tank side cover.
7 Remove the drain plug from the hydraulic tankand completely drain the tank into a containerof suitable capacity. Refer to Section 2,Specifications.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
8 Tag and disconnect the two suction hoses fromthe hydraulic tank.
9 Disconnect and plug the hydraulic hose at thereturn 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.
open closed
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Section 4 • Repair Procedures March 2005
REV A
4 - 86 GS-2668 RT • GS-3268 RT Part No. 52302
Steer Axle Components
11-1Yoke and Drive Motor
How to Remove the Yokeand Drive Motor
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
1 Block the non-steer wheels and center a liftingjack under the drive chassis at the steer end ofthe machine.
2 Loosen the wheel lug bolts. Do not removethem.
3 Raise the machine approximately6 inches / 5 cm. Place blocks under the chassisfor support.
Crushing hazard. The chassis willfall if not properly supported.
4 Remove the wheel lug bolts. Remove the tireand wheel assembly.
5 Tag, disconnect and plug the hoses from thedrive motor. Cap the fittings on the drive motor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly toallow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.
6 Support and secure the yoke and drive motorassembly to a lifting jack.
7 Remove the cotter pin from the tie rod clevispin.
Always use a new cotter pin wheninstalling a clevis pin.
8 Remove the retaining fastener from the loweryoke pivot pin.
9 Place a rod through the pin and twist to removethe pin.
10 Repeat steps 7 through 9 for the upper yokepivot pin.
11 Remove the yoke and drive motor assemblyfrom the machine.
Crushing hazard. The yoke anddrive motor assembly maybecome unbalanced and fall if notproperly supported and secured tothe lifting jack when it is removedfrom the machine.
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Section 4 • Repair ProceduresMarch 2005
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 87
STEER AXLE COMPONENTS
How to Remove a Drive MotorComponent damage hazard.Repairs to the motor should onlybe performed by an authorizeddealer.
Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
1 Loosen the wheel lug bolts. Do not removethem.
2 Block the non-steer end wheels and center alifting jack under the steer end of the machine.
3 Raise the machine approximately2 inches / 5 cm. Place blocks under the chassisfor support.
Crushing hazard. The chassis willfall if not properly supported.
4 Remove the wheel lug bolts. Remove the tireand wheel assembly.
5 Tag, disconnect and plug the hoses from thedrive motor. Cap the fittings on the drive motor.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
6 Remove the drive motor mounting fasteners.Remove the drive motor from the machine.
11-2Steer Cylinder
How to Remove theSteer Cylinder
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications.
1 Tag, disconnect and plug the hydraulic hosesfrom the steer cylinder. Cap the fittings on thecylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
2 Remove the pin retaining fasteners from thebarrel-end pivot pin. Use a soft metal drift toremove the pivot pin.
3 Remove the pin retaining fasteners from therod-end pivot pin. Use a soft metal drift toremove the pin.
4 Remove the steer cylinder from the machine.
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Section 4 • Repair Procedures March 2005
REV A
4 - 88 GS-2668 RT • GS-3268 RT Part No. 52302
STEER AXLE COMPONENTS
11-3Tie Rod
How to Remove the Tie Rod1 Remove the cotter pin from each tie rod clevis
pin. Remove the clevis pins.
Always use a new cotter pin wheninstalling a clevis pin.
2 Remove the tie rod.
How toPerform the Toe-in Adjustment(before serial number 33737)
Perform this procedure on a firm,level surface.
Perform this procedure with theplatform in the stowed position.
1 Straighten the steer wheels.
2 Block the tires at the non-steer end of themachine.
3 Measure the steer tires, front to front and backto back, using a measuring fixture.
4 Center a lifting jack under the steer end of thedrive chassis and raise the machine until thesteer tires are off of the ground.
5 Place blocks under the drive chassis forsupport.
6 Loosen the jam nut on the adjustable end of thetie rod.
7 Remove the cotter pin from the clevis pin at theadjustable end of the tie rod.
Always use a new cotter pin wheninstalling a clevis pin.
8 Slide the tie rod off of the yoke and adjust it byturning the end.
One half turn on the adjustableend equals approximately1/4 inch / 6.4 mm change in thefront and rear measurements.
9 Slide the tie rod onto the yoke. Install the clevispin.
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 endof the tie rod.
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Section 4 • Repair ProceduresMarch 2005
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 89
Non-steer Axle Components
12-1Drive Motor and Brake
How to Remove a Drive Motorand Brake
Component damage hazard.Repairs to the motor should onlybe performed by an authorizeddealer.
Component damage hazard. Thework area and surfaces where thisprocedure will be performed mustbe clean and free of debris thatcould get into the hydraulic systemand cause severe componentdamage. Dealer service isrecommended.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications
1 Block the steer wheels and center a lifting jackunder the drive chassis at the non-steer end ofthe machine.
2 Loosen the wheel lug bolts. Do not removethem.
3 Raise the machine approximately2 inches / 5 cm and place blocks under thedrive chassis for support.
4 Remove the wheel lug bolts. Remove the tireand wheel assembly.
5 Tag, disconnect and plug the hydraulic hosesfrom the drive motor and brake. Cap the fittingson the drive motor and brake.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly toallow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.
6 Support and secure the drive motor and brakeassembly to a lifting jack.
7 Remove the drive motor and brake mountingfasteners.
8 Remove the drive motor and brake assemblyfrom the machine.
Crushing hazard. The drive motorand brake assembly may becomeunbalanced and fall if not properlysupported and secured to thelifting jack when removed from themachine.
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Section 4 • Repair Procedures March 2005
REV A
4 - 90 GS-2668 RT • GS-3268 RT Part No. 52302
Outrigger Components
13-1Outrigger Cylinder
How to Remove an OutriggerCylinder (if equipped)
Perform this procedure with theplatform in the stowed positionand the outriggers fully retracted.
When removing a hose assemblyor fitting, the O-ring on the fittingand/or hose must be replaced andthen torqued to specificationduring installation. Refer toSection Two, Hydraulic Hose andFitting Torque Specifications
1 Lower the outrigger cylinder to be removed untilthe foot pad is resting on the ground. Do notapply any downward pressure.
2 Remove the outrigger limit switch. Do notdisconnect the wiring.
3 Remove the mounting fasteners from theoutrigger cover. Remove the cover.
4 Tag and disconnect the wiring from theoutrigger cylinder solenoid valve.
5 Tag, disconnect and plug the hydraulic hosesfrom the outrigger cylinder. Cap the fittings onthe cylinder.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly toallow the oil pressure todissipate gradually. Do notallow oil to squirt or spray.
6 Attach a lifting strap from an overhead crane tothe barrel end of the outrigger cylinder forsupport. Do not apply any lifting pressure.
7 Remove the outrigger mounting fasteners. Slidethe outrigger cylinder away from the machine.
Crushing hazard. The outriggercylinder may become unbalancedand fall if not properly supportedwhen removed from the machine.
If the outrigger cylinder is beingreplaced, remove the shoulder pinfrom the barrel end of theoutrigger cylinder and install it ontothe new cylinder.
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Section 4 • Repair ProceduresMarch 2005
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 4 - 91
14-1Brake Release Hand Pump ComponentsBefore serial number 41200: The brake release hand pump manifold is mounted underneath the batteryin the hydraulic tray.
After serial number 41199: The brake release hand pump manifold is mounted at the non-steer end ofthe chassis on the ground controls side of the machine.
Index SchematicNo. Description Item Function Torque
1 Shuttle valve ..................................... AE ............. Brake release circuit ............................ 45-50 in-lbs / 5 Nm
2 Check valve, pilot operated .............. AF ............. Manual brake release circuit ............ 65-70 in-lbs / 7-8 Nm
3 Hand pump ....................................... AG ............ Manual brake release .............................. 30 ft-lbs / 41 Nm
4 Needle valve ..................................... AH ............ Manual brake release enable .............. 45-50 in-lbs / 5 Nm
Brake Release Hand Pump Components
Before serial number GS6804-43184
After serial number 43183GS6804-
AE
AF
AG
AH
Note: 'alpha' callouts referto corresponding notes onthe hydraulic schematic
1
AG
AH
3
4
4
3
2
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Section 4 • Repair Procedures March 2005
4 - 92 GS-2668 RT • GS-3268 RT Part No. 52302
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Section 5 • Fault CodesMarch 2005
Part No. 52302 GS-2668 RT • GS-3268 RT 5 - 1
Fault Codes
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine.
Be sure that all necessary tools and testequipment are available and ready for use.
Be aware of the following hazards and followgenerally accepted safe workshop practices.
Crushing hazard. When testingor replacing any hydrauliccomponent, always supportthe structure and secure itfrom movement.
Electrocution hazard. Contactwith electrically charged circuitscould result in death or seriousinjury. Remove all rings, watchesand other jewelry.
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil tosquirt or spray.
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Unless otherwise specified, perform eachrepair procedure with the machine in thefollowing configuration:
· Machine parked on a firm, level surface
· Platform in the stowed position
· Key switch in the off position with the keyremoved
· The red Emergency Stop button in the offposition at both ground and platform controls
· Wheels chocked
· All external AC power supply disconnectedfrom the machine
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Section 5 • Fault Codes March 2005
5 - 2 GS-2668 RT • GS-3268 RT Part No. 52302
General Repair Process
About This SectionWhen a malfunction is discovered, the fault codecharts in this section will help a serviceprofessional pinpoint the cause of the problem. Touse this section, basic hand tools and certainpieces of test equipment are required—voltmeter,ohmmeter, pressure gauges.
Malfunctiondiscovered
Identifysymptoms
Troubleshoot
Performrepair
Return toservice problem
solved
problemstill exists
Inspectand test
LED Diagnostic Readout
FAULT CODES
The diagnostic readout displays numerical codesthat provide information about the machineoperating status and about malfunctions. The dotto the right of the numbers remain on when afault code is displayed.
The codes listed in the Fault Code Chartdescribe malfunctions and can aid introubleshooting the machine by pinpointing thearea or component affected.
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REV B
Section 5 • Fault CodesMarch 2005
Part No. 52302 GS-2668 RT • GS-3268 RT 5 - 3
Fault Code Chart(before serial number GS6803-42382)
Fault Code Fault Condition Possible Causes Solution
– – Normal operation.
01, 02 or 03 ECM does not allow machine to function.
Machine does not operate.
Defective ECM or platform controls.
Consult Genie Industries Service Department
10 ECM does not allow machine to function.
Engine will not start. Machine will not operate.
Ground controls engine start toggle switch fault, or is activated when the keyswitch is turned on.
Check for stuck toggle switch OR test or replace the toggle switch.
11 ECM does not allow machine to function.
Engine will not start. Machine will not operate.
Ground controls engine choke or glow plug toggle switch fault, or is activated when the keyswitch is turned on.
Check for stuck toggle switch OR test or replace the toggle switch.
12 ECM does not allow machine to function.
Engine will not start. Machine will not operate.
Ground controls platform up/down toggle switch fault, or is activated when the keyswitch is turned on.
Check for stuck toggle switch OR test or replace the toggle switch.
20 ECM does not allow machine to function.
Engine will not start. Machine will not operate from platform.
Platform controls engine choke or glow plug button fault, or is activated when the keyswitch is turned on.
Check or replace platform control panel switch board or replace the platform controls main circuit board.
21 ECM does not allow machine to function.
Engine will not start. Machine will not operate from platform.
Platform controls engine start button fault, or is activated when the keyswitch is turned on.
Check or replace platform control panel switch board or replace the platform controls main circuit board.
22 ECM does not allow machine to function.
Engine will not start. Machine will not operate from platform.
Platform controls steer left rocker switch fault, or is activated when the keyswitch is turned on.
Check for stuck steer microswitch OR test or replace the steer microswitch.
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REV B
Section 5 • Fault Codes March 2005
5 - 4 GS-2668 RT • GS-3268 RT Part No. 52302
FAULT CODE CHART(BEFORE SERIAL NUMBER GS6803-42382)
Fault Code Fault Condition Possible Causes Solution
23 ECM does not allow machine to function.
Engine will not start. Machine will not operate from platform.
Platform controls steer right rocker switch fault, or is activated when the keyswitch is turned on.
Check for stuck steer microswitch OR test or replace the steer microswitch.
26 ECM does not allow machine to function.
Engine will not start. Machine will not operate from platform.
Platform controls platform up/down toggle switch fault, or is activated when the keyswitch is turned on.
Check for stuck toggle switch OR test or replace the toggle switch.
27 ECM does not allow machine to function.
Engine will not start. Machine will not operate from platform.
Platform controls platform up/down fast speed function enable button fault, or is activated when the key switch is turned on.
Check for stuck function enable button OR test or replace the platform up/down fast speed function enable button.
28 ECM does not allow machine to function.
Engine will not start. Machine will not operate from platform.
Platform controls platform up/down slow speed function enable button fault, or is activated when the keyswitch is turned on.
Check for stuck function enable button OR test or replace the platform up/down slow speed function enable button.
29 ECM does not allow machine to function.
Engine will not start. Machine will not operate from platform.
Platform controls function enable switch fault, or is activated when the key switch is turned on.
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.
30 ECM does not allow machine to function.
Engine will not start. Machine will not operate from platform.
Platform controls joystick fault, or is activated when the keyswitch is turned on.
Check to make sure the joystick is in the center or neutral position.
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REV B
Section 5 • Fault CodesMarch 2005
Part No. 52302 GS-2668 RT • GS-3268 RT 5 - 5
FAULT CODE CHART(BEFORE SERIAL NUMBER GS6803-42382)
Fault Code Fault Condition Possible Causes Solution
40
No power output from ECM to the steer right valve coil OR ECM does not sense the steer right valve coil.
Machine will not steer right.
No power output from ECM to steer right coil (schematic item R) OR bad valve coil.
Check wiring and terminal at the steer right coil OR check wiring and terminal at ECM.
41
No power output from ECM to the steer left valve coil OR ECM does not sense the steer left valve coil.
Machine will not steer left.
No power output from ECM to steer left coil (schematic item R) OR bad valve coil.
Check wiring and terminal at the left right coil OR check wiring and terminal at ECM.
42
No power output from ECM to the platform up valve coil OR ECM does not sense the platform up valve coil.
Platform will not raise.
No power output from ECM to platform up coil (schematic item P) OR bad valve coil.
Check wiring and terminal at the platform up coil OR check wiring and terminal at ECM.
43
No power output from ECM to the brake valve coil OR ECM does not sense the brake valve coil.
Machine will not drive.
No power output from ECM to brake coil (schematic item T) OR bad valve coil.
Check wiring and terminal at the brake coil OR check wiring and terminal at ECM.
44
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.
Machine will not drive forward.
No power output from ECM to right front and left rear drive forward valve coil (schematic item A) OR bad valve coil.
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.
45
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 drive in reverse.
No power output from ECM to right front and left rear drive reverse valve coil (schematic item A) OR bad 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.
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REV B
Section 5 • Fault Codes March 2005
5 - 6 GS-2668 RT • GS-3268 RT Part No. 52302
FAULT CODE CHART(BEFORE SERIAL NUMBER GS6803-42382)
46
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.
Machine will not drive forward.
No power output from ECM to left front and right rear drive forward valve coil (schematic item B) OR bad valve coil.
Check wiring and terminals to left front and right rear drive forward valve coil OR check the wiring and terminal at the ECM OR replace the valve coil.
47
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.
Machine will not drive in reverse.
No power output from ECM to left front and right rear drive reverse valve coil (schematic item B) OR bad 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.
48
No power output from ECM to the platform down valve coil OR ECM does not sense the platform down valve coil.
Platform will not lower.
No power output from ECM to platform down coil OR bad valve coil.
Check wiring and terminal at the platform down coil OR check wiring and terminal at ECM.
49
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.
No power output from ECM to parallel/series valve coil (schematic item X) OR bad valve coil.
Check wiring and terminal at the parallel/series valve coil (schematic item X) OR replace valve coil.
50
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.
No power output from ECM to parallel/series valve coil (schematic item V) OR bad valve coil.
Check wiring and terminal at the parallel/series valve coil (schematic item V) OR replace valve coil.
Fault Code Fault Condition Possible Causes Solution
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REV B
Section 5 • Fault CodesMarch 2005
Part No. 52302 GS-2668 RT • GS-3268 RT 5 - 7
FAULT CODE CHART(BEFORE SERIAL NUMBER GS6803-42382)
51
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.
No power output from ECM to parallel/series valve coil (schematic item W) OR bad valve coil.
Check wiring and terminal at the parallel/series valve coil (schematic item W) OR replace valve coil.
52
No power output from ECM to the porportional valve coil OR ECM does not sense the porportional valve coil.
Machine will not drive.
No power output from ECM to proportional valve coil (schematic item T) OR bad valve coil.
Check wiring and terminal at the proportional valve coil (schematic item T) OR replace valve coil.
60
No power output from ECM to the LPG shut-off valve coil OR ECM does not sense the LPG shut-off valve coil.
Engine will not start or run on LPG.
No power output from ECM to LPG shut-off coil OR bad coil.
Check wiring at the LPG shut-off valve coil OR replace LPG valve coil.
66 ECM does not allow machine to function.
Engine will not start or run OR engine runs then shuts off.
Low engine oil pressure OR defective oil pressure switch.
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 the oil pressure switch.
Fault Code Fault Condition Possible Causes Solution
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REV B
Section 5 • Fault Codes March 2005
5 - 8 GS-2668 RT • GS-3268 RT Part No. 52302
FAULT CODE CHART(BEFORE SERIAL NUMBER GS6803-42382)
Fault Code Fault Condition Possible Causes Solution
67 ECM does not allow machine to function.
Engine will not start or run OR engine runs then shuts off.
High engine temperature OR defective water temperature switch.
Check the engine radiator coolant level OR check wiring and terminal at the water temperature switch OR check the wiring and terminal at the ECM OR replace the water temperature switch.
68 ECM does not allow machine to function.
All functions do not operate.
Low supply voltage to ECM.
Check battery or alternator condition, E Stop relay 1 & 2 terminals.
69 ECM does not allow machine to function.
Engine starts and runs then shuts down.
Engine idle RPM too low.
Consult Genie Industries Service Department
70 ECM does not allow machine to function.
Engine starts and runs then shuts down.
Engine RPM too high.Consult Genie Industries Service Department
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Section 5 • Fault CodesMarch 2005
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 5 - 9
Fault Code Chart(after serial number GS6803-42381)
Fault Code LED Condition Result Solution
SYSTEM READY Green Normal operation
01 INTERNAL ECU
FAULT
Red Internal ECM error. System shutdown. Replace ECM.
02 PLATFORM ECU
FAULT Red Platform/ECM communication
error. System shutdown. Troubleshoot control cable OR
troubleshoot platform controls.
20 CHASSIS START
SW FAULT Red Engine start button fault at
ground controls. Engine will not start. Replace ECM.
21 CHASSIS CHOKE
SW FAULT Red Starting aid button fault at
ground controls. Starting aid disabled. Replace ECM.
22 CHASSIS UP SW
FAULT Red Up switch fault at ground
controls. Platform up function inoperable. Replace ECM.
23 CHASSIS LIFT SW
FAULT Red Platform up/down enable
button fault at ground controls. Platform up/down functions disabled.
Replace ECM.
24 DOWN SW FAULT Red Down switch fault at ground
controls. Platform down function disabled. Replace ECM.
25 LEFT TURN SW
FAULT Red Left turn switch fault. Malfunctioning steer left
microswitch. Troubleshoot steer left microswitch.
26 RIGHT TURN SW
FAULT Red Right turn switch fault. Malfunctioning steer right
microswitch. Troubleshoot steer right microswitch.
27 DRIVE ENABLE
SW FLT
Red Function enable switch on joystick is activated when machine is turned on.
Machine functions disabled. Release function enable switch on joystick before power up OR replace joystick.
28 OFF NEUTRAL
DRIVE JOYSTICK
Red Drive joystick off neutral when machine is turned on. Machine functions disabled.
Release joystick before power up OR replace joystick.
29 PLATFORM LIFT
SW FAULT
Red Lift enable button fault at the platform controls. Lift function disabled. Troubleshoot button OR replace printed
circuit board at platform controls.
30 OFF NEUTRAL LIFT JOYSTICK
Red Up/down switch off neutral. Up/down function disabled. Replace up/down switch at platform controls.
31 PLATFORM CHOKE SW
FAULT
Red Starting aid fault at the platform controls.
Starting aid disabled. Troubleshoot button OR replace printed circuit board at platform controls.
32 PLATFORM
START SW FAULT
Red Engine start button fault at platform controls.
Engine will not start. Troubleshoot button OR replace printed circuit board at platform controls.
33 LEFT FRONT
OUTRIG SW FLT
Red Left front outrigger enable button fault at platform controls.
Outriggers disabled. Troubleshoot button OR replace printed circuit board at platform controls.
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Section 5 • Fault Codes March 2005
REV A
5 - 10 GS-2668 RT • GS-3268 RT Part No. 52302
FAULT CODE CHART(AFTER SERIAL NUMBER GS6803-42381)
Fault Code LED Condition Result Solution 34
RIGHT FRONT OUTRIG SW FLT
Red Right front outrigger enable button fault at platform controls.
Outriggers disabled. Troubleshoot button OR replace printed circuit board at platform controls.
35 LEFT REAR
OUTRIG SW FLT
Red Left rear outrigger enable button fault at platform controls.
Outriggers disabled. Troubleshoot button OR replace printed circuit board at platform controls.
36 RIGHT REAR
OUTRIG SW FLT
Red Right rear outrigger enable button fault at platform controls.
Outriggers disabled. Troubleshoot button OR replace printed circuit board at platform controls.
37 AUTO LEVEL
SWITCH FAULT
Red Outrigger autolevel enable button fault at platform controls.
Outriggers disabled. Troubleshoot button OR replace printed circuit board at platform controls.
49 DRIVE COIL 1
FAULT
Red Drive coil 1 (Y1) fault. High torque drive function will not operate. Troubleshoot coil OR wiring.
50 DRIVE COIL 2
FAULT
Red Drive coil 2 (Y1A) fault. High torque drive function will not operate.
Troubleshoot coil OR wiring.
51 DRIVE COIL 3
FAULT
Red Drive coil 3 (Y1B) fault. High torque drive function will not operate.
Troubleshoot coil OR wiring.
52 FUNC PROP COIL
FAULT
Red Proportional coil (Y9) fault. Lift and outrigger functions are disabled.
Troubleshoot coil OR wiring.
54 UP COIL FAULT
Red Up coil (Y8) fault. Platform will not raise. Troubleshoot coil OR wiring.
55 DOWN COIL
FAULT
Red Down coil (Y7) fault. Platform will not lower. Troubleshoot coil OR wiring.
56 RIGHT TURN COIL
FAULT
Red Right turn coil (Y3) fault. Machine will not turn right. Troubleshoot coil OR wiring.
57 LEFT TURN COIL
FAULT
Red Left turn coil (Y4) fault. Machine will not turn left. Troubleshoot coil OR wiring.
58 BRAKE COIL
FAULT
Red Brake release coil (Y2) fault. Brakes will not release. Troubleshoot coil OR wiring.
60 FORWARD 1 COIL
FAULT
Red Forward 1 coil (Y6) fault. Drives slow or not at all when elevated.
Troubleshoot coil OR wiring.
61 REVERSE 1 COIL
FAULT
Red Reverse 1 coil (Y5) fault. Drives slow or not at all when elevated.
Troubleshoot coil OR wiring.
62 FORWARD 2 COIL
FAULT
Red Forward 2 coil (Y6A) fault. Drives slow or not at all when elevated.
Troubleshoot coil OR wiring.
63 REVERSE 2 COIL
FAULT
Red Reverse 2 coil (Y5A) fault. Drives slow or not at all when elevated. Troubleshoot coil OR wiring.
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Section 5 • Fault CodesMarch 2005
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 5 - 11
FAULT CODE CHART(AFTER SERIAL NUMBER GS6803-42381)
Fault Code LED Condition Result Solution 66
LOW OIL PRESSURE
Red Low oil pressure. Engine stops.
Check the engine oil level OR check wiring from the oil pressure switch to ECM OR replace the oil pressure switch.
67 HIGH COOLANT TEMPERATURE
Red High coolant temperature. High engine temperature OR defective engine coolant or oil temperature switch.
Gasoline/LPG models: Check the engine radiator coolant level OR check the wiring from the water temperature switch to ECM OR replace the water temperature switch. Diesel models: Check the engine oil level OR check the wiring from the oil temperature switch to ECM OR replace the oil temperature switch.
68 LOW ECU VOLTAGE
Red Low ECM voltage. System shutdown. Charge battery.
69 LOW ENGINE
RPM Red Low RPM. Engine idle RPM too low. Consult Genie Industries Service
Department.
70 HIGH ENGINE
RPM Red High RPM. Engine RPM too high.
Consult Genie Industries Service Department.
80 LEFT FRONT
OTRG COIL FLT Red Left front outrigger coil (Y35)
fault. Left front outrigger disabled. Troubleshoot coil OR wiring.
81 LEFT REAR OTRG
COIL FLT Red Left rear outrigger coil (Y33)
fault. Left rear outrigger disabled. Troubleshoot coil OR wiring.
82 RIGHT FRONT
OTRG COIL FLT Red Right front outrigger coil (Y36)
fault. Right front outrigger disabled. Troubleshoot coil OR wiring.
83 RIGHT REAR
OTRG COIL FLT Red
Right rear outrigger coil (Y34) fault. Right rear outrigger disabled. Troubleshoot coil OR wiring.
84 OUTRIGGER EXT
COIL FLT Red Outrigger extend coil (Y40)
fault. Outrigger extend function disabled. Troubleshoot coil OR wiring.
85 OUTRIGGER RET
COIL FLT Red Outrigger retract coil (Y39)
fault. Outrigger retract function disabled. Troubleshoot coil OR wiring.
86 OUTRIGGER
SLOW COIL FLT Red Outrigger slowdown coil (Y44)
fault. Outrigger slow extend function disabled. Troubleshoot coil OR wiring.
90 2 SPEED COIL
FAULT Red 2 speed coil (Y1) fault High torque drive function disabled. Troubleshoot coil OR wiring.
92 DRIVE FWD PROP
COIL FAULT Red Drive pump forward
proportional coil (Y51) fault Drive forward function disabled. Troubleshoot coil OR wiring.
93 DRIVE REV PROP
COIL FAULT Red Drive pump reverse
proportional coil (Y51) fault Drive reverse function disabled. Troubleshoot coil OR wiring.
94 MACHINE TYPE
FAULT Red Wrong machine type selected Machine will not operate. Correct selection.
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Section 5 • Fault Codes March 2005
5 - 12 GS-2668 RT • GS-3268 RT Part No. 52302
This page intentionally left blank.
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 1
Schematics
Observe and Obey:
Troubleshooting and repair procedures shall becompleted by a person trained and qualified onthe repair of this machine.
Immediately tag and remove from service adamaged or malfunctioning machine.
Repair any machine damage or malfunctionbefore operating the machine.
Before Troubleshooting:
Read, understand and obey the safety rulesand operating instructions in the appropriateoperator's manual on your machine.
Be sure that all necessary tools and testequipment are available and ready for use.
About This SectionThere are two groups of schematics in this section.An illustration legend precedes each group ofdrawings.
Electrical Schematics
Electrocution hazard. Contact withelectrically charged circuits couldresult in death or serious injury.Remove all rings, watches andother jewelry.
Hydraulic Schematics
Bodily injury hazard. Sprayinghydraulic oil can penetrate andburn skin. Loosen hydraulicconnections very slowly to allowthe oil pressure to dissipategradually. Do not allow oil to squirtor spray.
General Repair Process
Malfunctiondiscovered
Identifysymptoms
Troubleshoot
Performrepair
Return toservice problem
solved
problemstill exists
Inspectand test
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March 2005Section 6 • Schematics
REV A
6 - 2 GS-2668 RT • GS-3268 RT Part No. 52302
Electronic Control Module Layout(before serial number GS6803-42382)
J4Electronic Control Module
J3
J2J1
Engine
Down limit switch
Up limit switch
Platform controls
Function manifold
Levelsensor
Horn
Ground controls
Flashing beacon
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 3
Electronic Control Module Pin-Out Legend(before serial number GS6803-42382)
!!
"
# $ ! !!
%
%
%
%
%
%
% &'(
% ) '(
%"
%#
% *
%
& ( ! +
& ( ! +%
& ( ! +&
& ( ! +(
& ( ! +'
& ( ! +,
& ( ! +-
& ( ! +*
&" ( ! +.
&# ( ! +
&
&
!
" #!
$
%#&'#%
(#
#'#"
)
*#
+,#$
! +'"
+,#
" )
$ )
)
)
- #
- #
- #
- #
- )
- )
-! .#
- .#
-" )
-$ )
- #
- #
! ""
# "" $
# %" "" $
# &
# '
# %" ""
#! (""
) &
) &
) &
) &
) &
)! &
! "
#
# $
# "
#
#
#! %&'
()
"
! "
1A
12
B
C
1
1
12
12
1A
12
B
C
1
1
12
12
C
1A
B1
1
6
6
66
C
1A
B1
1
6
6
66
J4 J3
J2J1
Electronic Control Module
18 pin connector (J3 and J4)
36 pin connector (J1 and J2)
C
1A
B 1
1
6
6
66
1A 12
B
C
1
1
12
126
6
6
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March 2005Section 6 • Schematics
REV A
6 - 4 GS-2668 RT • GS-3268 RT Part No. 52302
Electronic Control Module Layout(after serial number GS6803-42381)
J2J1
Engine
Down limitswitchFlashing beacons
Platform controls
To outriggers
Electronic Control Module
Generator
Outriggers and manifold
Function manifold
Levelsensor
Horn
Ground controlsand ECM
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 5
Electronic Control Module Pin-Out Legend(after serial number GS6803-42381)
1A 12
B
C
1
1
12
126
6
6
1A
12
B
C
1
1
12
12
1A
12
B
C
1
1
12
12
J2J1
J1 Connector (36 pin)
Pin Description A1 Right turn coil Y3 (output) A2 Left turn coil Y4 (output) A3 Up coil Y8 (output) A4 Brake coil Y2 (output) A5 Drive forward1 Y6 (output) A6 Drive reverse1 Y5 (output) A7 Drive forward2 Y6A (output) A8 Drive reverse2 Y5A (output) A9 Down coil Y7 (output) A10 Drive coil1 Y1 (output) A11 Drive coil Y1A (output) A12 Drive coil Y1B (output)
B1 Generator coil Y29 (output) B2 Plug B3 Proportional flow control Y9
(output) B4 Plug B5 Right front outrigger coil
Y36 (output) B6 Outrigger extend coil Y40
(output) B7 Outrigger retract coil Y39
(output) B8 Outrigger extend coil Y40
(output) B9 Left front outrigger coil Y35
(output) B10 Left rear outrigger coil Y33
(output) B11 Right rear outrigger coil Y34
(output) B12 LPG select OR
Diesel shut off coil (output)
C1 Plug C2 Platform overload (input) C3 Right front outrigger limit
switch LS13 (input) C4 Right rear outrigger limit
switch LS15 (input) C5 Left front outrigger limit
switch LS12 (input) C6 Left rear outrigger limit
switch LS14 (input) C7 Alternator (input) C8 Engine oil pressure SW2
(input) C9 Engine water temp SW1 OR
oil temp SW3 (input) C10 Plug C11 Fuel coil (output) C12 Plug
J2 Connector (36 pin)
Pin Description A1 Up limit switch LS5 (input) A2 Down limit switch LS6
(input) A3 Aux down power (input) A4 Aux down relay CR23
terminal 86 (output) A5 Key switch terminal 3 (input) A6 Level sensor S7 (white)
(input) A7 Plug A8 Plug A9 Plug A10 Platform controls (ground)
(input) A11 Platform controls (data +)
(input) A12 Platform controls (data -)
(input)
B1 Level sensor S8 (blue) (input)
B2 Level sensor S8 (black) (input)
B3 Level sensor S8 (yellow) (input)
B4 Plug B5 Plug B6 Plug B7 Engine start relay CR1
terminal 86 (output) B8 Ignition relay CR8 terminal
86 (output) B9 Engine high idle (output) B10 Level sensor S8 (red)
(output) B11 Horn relay CR5 terminal 86
(output) B12 Alarm (output)
C1 System power (input) C2 System power (input) C3 System power (input) C4 Engine starting aid (output) C5 Oscillate stowed relay CR84
terminal 86 (output) C6 Oscillate raised relay CR85
terminal 86 (output) C7 Ground (output) C8 Plug C9 Plug C10 Auxiliary down relay CR23
terminal 87 (output) C11 Flashing beacons FS1
(output) C12 ECM power (input)
Electronic Control Module
Pin layout36 pin connector
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March 2005Section 6 • Schematics
REV A
6 - 6 GS-2668 RT • GS-3268 RT Part No. 52302
Wiring Diagram - Platform Control Box(before serial number GS6803-42382)
Gasoline/LPG modelsbefore serial number 1241andDiesel modelsbefore serial number 1055
Gasoline/LPG modelsafter serial number 1240
andDiesel models
after serial number 1054
BK
RD
TO COIL CORD ASSEMBLY
P2EMERGENCY STOP
BUTTON
JC4JOYSTICK
CONTROLLER
D7VOLTAGEREGULATOR
U3PLATFORMCONTROLS
CIRCUITBOARD
RD
2 1N
C
SW25DIP SWITCH
1 2 3 4 5 6 7 8
ON DIP
PP
BN
OR
BN
WH/BK
WH/RD
WH/YL
OR
WH/BL
PP
WH
RD
WH
WH
H1ALARM
BN13FUNCTION
ENABLE/LOW SPEED
BUTTON
BN12FUNCTION
ENABLE/HIGH SPEED
BUTTON
TS20PLATFORMUP/DOWNTOGGLESWITCH
BK
RD
YL
BK
BL
BK
BK
WH
BL
RD
GN
P2EMERGENCY STOP
BUTTON
JC4JOYSTICK
CONTROLLER
D7VOLTAGEREGULATOR
U3PLATFORMCONTROLS
CIRCUITBOARD
RD
RD WH
BK
WH
H1ALARM
BN13FUNCTION
ENABLE/LOW SPEED
BUTTON
BN12FUNCTION
ENABLE/HIGH SPEED
BUTTON
TS20PLATFORM UP/DOWN
TOGGLE SWITCH(MODELS WITHOUT OUTRIGGERS)
TS21PLATFORM UP/DOWN / OUTRIGGER UP/DOWN
TOGGLE SWITCH(MODELS WITH OUTRIGGERS)
- OR -
2 1N
C
BK
RD
YL
SW25DIP SWITCH
WH
BN
WH/BK
WH/RD
WH/BL
OR
PP
BK
BL
BK
1 2 3 4 5 6 7 8
ON DIP
BK
RD
WH
BL
YL
TO COIL CORD ASSEMBLY
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 7
Wiring Diagram - Platform Control Box(after serial number GS6803-42381)
J5
J3
J2
J1
5
1
4
1
1 14
1
6
1
2
NC
P2EMERGENCYSTOP
H1ALARM
JC1JOYSTICKCONTROLLER
U3PLATFORMCONTROLSCIRCUITBOARD
OR
WH
WH/BL
PP
GY
BN
YL
WH
RD
BK
BL
OR
RD
BK
BKYLBL
RD
RD
BK
BL
GY
TS20
TS21OR
COIL CORD ASSEMBLY
TS20 PLATFORM UP/DOWN TOGGLE SWITCH (MODELS WITHOUT OUTRIGGERS)
TS21 PLATFORM UP/DOWN / OUTRIGGER UP/DOWN TOGGLE SWITCH (MODELS WITH OUTRIGGERS)
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March 2005Section 6 • Schematics
REV A
6 - 8 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical Schematics Abbreviation and Wire Color Legends
! " #$ % & % ' ()% "!' *' +($ ,
- -).+++
-)%/-
-+ -0% %+++1 -"0 %2221
--,
-, -, -, -,*3 -, -,")) -, -,#$ -,4-5
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![Page 173: Service Manual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · in this manual and the appropriate Operator's Manual on your machine will result in death](https://reader035.fdocuments.us/reader035/viewer/2022062413/5aad9e347f8b9adb688b4b95/html5/thumbnails/173.jpg)
March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 9
Electrical Symbols Legend
()
-
(+)
A A
C C
B B
D D
E E
P1
G6 G6
M4
F
RD1
G
(+)
()
-
S32
S33
S34
S35
S39
S36
S38
S37
M3
KS1PLATFORM
GROUND
GROUND
CB120A
87
30
85
86
Emergency Stopbutton
Wire connection
No connection(circuits crossing)
Diode
Circuit breaker
LED
12V DCBattery
Key switch
Control relay
Button
Pressure switch
Temperature switch
Capacitor
Limit switch
Work lights
Solenoid valve withspike supression
diode
Solenoid valveno diode
Solenoid valve withredundant coils
Electro-mechanicalsolenoid
Alternator
Ignition coil
Distributor
Motor or pump
Spark plugs
Glow plug(s)
Starter motor
DIP switch
Hour meter
Level sensor(models without outriggers)
Flashing beacon
Horn or alarm
Quick disconnect
Toggle switch
Voltage regulator
Potentiometer
Resistor
![Page 174: Service Manual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · in this manual and the appropriate Operator's Manual on your machine will result in death](https://reader035.fdocuments.us/reader035/viewer/2022062413/5aad9e347f8b9adb688b4b95/html5/thumbnails/174.jpg)
March 2005Section 6 • Schematics
REV B
6 - 10 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (before serial number 21161)Part 1 of 2
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
KS1PLATFORM
GROUND
87
30
85
86
TS54TS56TS52
CB2
1A
CB120A
33000 ufC2
ENGINESTART
CR1
AUXILIARYPLATFORMDOWN(GS-3268RT ONLY)
BN23
BA
TT
ER
Y1
2V
DC
B1 D1
D1
J4
-A3
CH
OK
E
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
J1
-C1
\C4
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3CH
OK
E
IGNITIONCR8
ECMPOWER TOCR43
ENGINE RUNCR25
STARTINGAID
CR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
2000R7
B112V DC
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
SW2
J4
-B2
SW2
J4
-B1
N.C.N.O.
OIL
PR
ES
SU
RE
SW
ITC
H
SW1
SW1
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
M4
J4
-C1
Q1
J4
-C2
FU
EL
PU
MP
M4 Q2
Q1 Q2
Q7
Q7HO
UR
ME
TE
R
G6
G6
L30
WO
RK
LIG
HT
S(O
PT
ION
)
L30
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES0116F
EN
GIN
ES
TA
RT
ER
M3
M3 SP
AR
KP
LU
G(S
)
IGN
ITIO
NC
OIL
U19 DIS
TR
IBU
TO
R
U26
GU26
SP
AR
KP
LU
G(S
)
U20IGN
ITIO
NC
OIL
DIS
TR
IBU
TO
R
U19
LP
GS
EL
EC
T
GA
SO
LIN
ES
EL
EC
T
![Page 175: Service Manual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · in this manual and the appropriate Operator's Manual on your machine will result in death](https://reader035.fdocuments.us/reader035/viewer/2022062413/5aad9e347f8b9adb688b4b95/html5/thumbnails/175.jpg)
March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 11
Electrical SchematicGasoline/LPG Models (before serial number 21161)
Part 2 of 2
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
TS67
DA
TA
LIN
K(-)
YL
J3
-A5
FUNCTIONENABLE
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
J3
-A2
J3
-A1
J3
-A3
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D(1
)
Y6
J1
-A5
DR
IVE
RE
VE
RS
E(1
)
Y5
J1
-A6
DR
IVE
FO
RW
AR
D(2
)
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E(2
)
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
G8
DISPLAYDIAGNOSTIC
N.C.N.C.
LS5PLATFORM
UP
LS6PLATFORM
DOWNJ1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
ELECTRONIC CONTROL MODULE
U5
N.C.
LS1EXTENSION
DECK
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES0116F
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT7
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN9
PIN24
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
PP
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
OR
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS
PLATFORM EXT/RET ENABLE BN16PIN25
STARTING AID BN3PIN29
LPG LED L22
LPG SELECT BN14PIN13
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March 2005Section 6 • Schematics
REV B
6 - 12 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (from serial number 21161 to 21837)Part 1 of 2
J1
-C11
,C1
2
J4
-C4
J2
-A5
J4
-B4
J4
-C3
J4
-A5
J4
-B5
KS1PLATFORM
GROUND
87
30
85
86
TS54TS56TS52
CB2
1A
CB120A
ENGINESTART
CR1
AUXILIARYPLATFORMDOWN(GS-3268RT ONLY)
BN23
J4
-A3
CH
OK
E
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
J1
-C1
\C4
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3CH
OK
E
IGNITIONCR8
ECMPOWER TOCR43
ENGINE RUNCR25
STARTINGAID
CR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
SW2
J4
-B2
SW2
J4
-B1
N.C.N.O.
OIL
PR
ES
SU
RE
SW
ITC
H
SW1
SW1
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
M4
J4
-C1
J4
-C2
FU
EL
PU
MP
M4
Q1 Q2
Q7
Q7
L30
WO
RK
LIG
HT
S(O
PT
ION
)
L30
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES0116G
ALT
ER
NA
TO
R
F
R
BA
TT
ER
Y1
2V
DC
B1 D1
D1
B112V DC
HO
UR
ME
TE
R
G6
G6SP
AR
KP
LU
G(S
)
IGN
ITIO
NC
OIL
U19 DIS
TR
IBU
TO
R
U26
GU26
SP
AR
KP
LU
G(S
)
U20IGN
ITIO
NC
OIL
DIS
TR
IBU
TO
R
U19
EN
GIN
ES
TA
RT
ER
M3
M3 Q1 Q2
LP
GS
EL
EC
T
GA
SO
LIN
ES
EL
EC
T
![Page 177: Service Manual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · in this manual and the appropriate Operator's Manual on your machine will result in death](https://reader035.fdocuments.us/reader035/viewer/2022062413/5aad9e347f8b9adb688b4b95/html5/thumbnails/177.jpg)
March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 13
Electrical SchematicGasoline/LPG Models (from serial number 21161 to 21837)
Part 2 of 2
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
TS67
DA
TA
LIN
K(-)
YL
J3
-A5
FUNCTIONENABLE
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
J3
-A2
J3
-A1
J3
-A3
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D(1
)
Y6
J1
-A5
DR
IVE
RE
VE
RS
E(1
)
Y5
J1
-A6
DR
IVE
FO
RW
AR
D(2
)
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E(2
)
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
G8
DISPLAYDIAGNOSTIC
N.C.N.C.
LS5PLATFORM
UP
LS6PLATFORM
DOWNJ1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
ELECTRONIC CONTROL MODULE
U5
N.C.
LS1EXTENSION
DECK
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES0116G
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT7
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN9
PIN24
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
PP
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
OR
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS
PLATFORM EXT/RET ENABLE BN16PIN25
STARTING AID BN3PIN29
LPG LED L22
LPG SELECT BN14PIN13
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March 2005Section 6 • Schematics
REV B
6 - 14 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (from serial number 21838 to 38464)Part 1 of 3
J1
-C11
,C1
2
J4
-C4
J2
-A5
J4
-B4
J4
-C3
J4
-A5
J4
-B5
KS1PLATFORM
GROUND
87
30
85
86
TS54TS56TS52
CB2
1A
CB120A
ENGINESTART
CR1
AUXILIARYPLATFORMDOWN(GS-3268RT ONLY)
BN23
J4
-A3
CH
OK
E
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
J1
-C1
\C4
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3CH
OK
E
IGNITIONCR8
ECMPOWER TOCR43
ENGINE RUNCR25
STARTINGAID
CR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
SW2
J4
-B2
SW2
J4
-B1
N.C.N.O.
OIL
PR
ES
SU
RE
SW
ITC
H
SW1
SW1
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
M4
J4
-C1
J4
-C2
FU
EL
PU
MP
M4
Q1 Q2
Q7
Q7
L30
WO
RK
LIG
HT
S(O
PT
ION
)
L30
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES0116N
ALT
ER
NA
TO
R
F
R
BA
TT
ER
Y1
2V
DC
B1 D1
D1
EN
GIN
ES
TA
RT
ER
M3
M3
B112V DC
SP
AR
KP
LU
G(S
)
IGN
ITIO
NC
OIL
U19 DIS
TR
IBU
TO
R
U26
GU26
SP
AR
KP
LU
G(S
)
U20IGN
ITIO
NC
OIL
DIS
TR
IBU
TO
R
U19
HO
UR
ME
TE
R
G6
G6
CB2 CHANGED TO 7 AMP
AFTER SERIAL NUMBER 33850
Q1 Q2
LP
GS
EL
EC
T
GA
SO
LIN
ES
EL
EC
T
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 15
Electrical SchematicGasoline/LPG Models (from serial number 21838 to 38464)
Part 2 of 3
TS67FUNCTIONENABLE
J3
-A2
J3
-A1
J3
-A3
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
N.C.N.C.
LS5PLATFORM
UP
LS6PLATFORM
DOWN
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
ELECTRONIC CONTROL MODULE
U5
NOTE: LS5, LS1USED ON
GS-3268AFTER SERIALNUMBER 26562
ONLY
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
N.C.
LS1EXTENSION
DECK
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
(OPTION)
ES0116N
MODELS
WITHOUT
OUTRIGGERS
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March 2005Section 6 • Schematics
REV B
6 - 16 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (from serial number 21838 to 38464)Part 3 of 3
PLATFORM CONTROLS
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT7
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
LPG LED L22
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW25DIPSWITCH
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
LPG SELECT BN14
HIGH TORQUE BN6PIN23
PIN24
PIN13
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
(GASOLINE/LPG MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT7
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
LPG LED L22
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
LPG SELECT/RR OUTRIGGER BN22
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM & OUTRIGGERUP/DOWN TS21
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(GASOLINE/LPG MODELS WITH OUTRIGGERS)
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 17
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March 2005Section 6 • Schematics
REV B
6 - 18 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (from serial number 38465 to 41199)Part 1 of 3
J1
-C11
,C1
2
J4
-C4
J2
-A5
J4
-B4
J4
-C3
J4
-A5
J4
-B5
KS1PLATFORM
GROUND
87
30
85
86
TS54TS56TS52
CB2
7A
CB120A
ENGINESTART
CR1
AUXILIARYPLATFORMDOWN(GS-3268RT ONLY)
BN23
J4
-A3
CH
OK
E
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
J1
-C1
\C4
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3CH
OK
E
IGNITIONCR8
ECMPOWER TOCR43
ENGINE RUNCR25
STARTINGAID
CR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
SW2
J4
-B2
SW2
J4
-B1
N.C.N.O.
OIL
PR
ES
SU
RE
SW
ITC
H
SW1
SW1
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
M4
J4
-C1
LP
GS
EL
EC
T
Q1
J4
-C2
FU
EL
PU
MP
M4
GA
SO
LIN
ES
EL
EC
T
Q2
Q1 Q2
Q7
Q7
L30
WO
RK
LIG
HT
S(O
PT
ION
)
L30
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES0116S
ALT
ER
NA
TO
R
F
R
BA
TT
ER
Y1
2V
DC
B1 D1
D1
EN
GIN
ES
TA
RT
ER
M3
M3
B112V DC
SP
AR
KP
LU
G(S
)
IGN
ITIO
NC
OIL
U19 DIS
TR
IBU
TO
R
U26
GU26
SP
AR
KP
LU
G(S
)
U20IGN
ITIO
NC
OIL
DIS
TR
IBU
TO
R
U19
HO
UR
ME
TE
R
G6
G6
Y10
AU
XIL
LIA
RY
PL
AT
FO
RM
DO
WN
Y10A
(GS
-32
68
ON
LY)
AU
XIL
LIA
RY
PL
AT
FO
RM
DO
WN
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 19
Electrical SchematicGasoline/LPG Models (from serial number 38465 to 41199)
Part 2 of 3
TS67FUNCTIONENABLE
J3
-A2
J3
-A1
J3
-A3
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
N.C.N.C.
LS5PLATFORM
UP
LS6PLATFORM
DOWN
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
ELECTRONIC CONTROL MODULE
U5
NOTE: LS5, LS1USED ON
GS-3268AFTER SERIALNUMBER 26562
ONLY
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
N.C.
LS1EXTENSION
DECK
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
(OPTION)
ES0116S
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
MODELS
WITHOUT
OUTRIGGERS
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March 2005Section 6 • Schematics
REV B
6 - 20 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (from serial number 38465 to 41199)Part 3 of 3
PLATFORM CONTROLS
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT7
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
LPG LED L22
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW25DIPSWITCH
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
LPG SELECT BN14
HIGH TORQUE BN6PIN23
PIN24
PIN13
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
(GASOLINE/LPG MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT7
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
LPG LED L22
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
LPG SELECT/RR OUTRIGGER BN22
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM & OUTRIGGERUP/DOWN TS21
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(GASOLINE/LPG MODELS WITH OUTRIGGERS)
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 21
This page intentionally left blank.
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March 2005Section 6 • Schematics
REV B
6 - 22 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (from serial number 41200 to 41823)Part 1 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES0116U
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
KS1PLATFORM
GROUND
87
30
85
86
G6
G6
CB120A
ENGINESTART
CR1
BA
TT
ER
Y1
2V
DC
B1 D1
D1
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3
IGNITIONCR8
ECMPOWER TOCR43
ENGINE RUNCR25
PLUGGLOWCR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
()-
(+) B112V DC
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
OIL
PR
ES
SU
RE
SW
ITC
H
SW2
J4
-B2
SW2
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
SW1
J4
-B1
SW1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
Y10 Y10A
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
J1-C1\C4
BN68START
J4
-A2
L30
L30WO
RK
LIG
HT
S(O
PT
ION
)
EN
GIN
ES
TA
RT
ER
M3
M3 SP
AR
KP
LU
G(S
)
IGN
ITIO
NC
OIL
U19 DIS
TR
IBU
TO
R
U26
GU26
SP
AR
KP
LU
G(S
)
U20IGN
ITIO
NC
OIL
DIS
TR
IBU
TO
R
U19
CR
17
87
30
85
86
SW4
SW4
HY
DR
AU
LIC
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
M1
N.O.
F9A20A
HY
DR
AU
LIC
OIL
CO
OL
ING
FA
N(O
PT
ION
)
M1
HYDRAULICOIL COOLER
(OPTION)
CH
OK
E
Q7
Q7
1
2
3
J1
-A9
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 23
Electrical SchematicGasoline/LPG Models (from serial number 41200 to 41823)
Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES0116U
J3
-A1
J3
-A3
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
ELECTRONIC CONTROL MODULE
U5
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
(OPTION)
J3
-A2
N.C.
LS6PLATFORM
DOWN
P1EMERGENCY
STOP
BN90GLOWPLUG
TS54HIGHIDLE
BN83PLATFORM
UP
BN84PLATFORM
DOWN
J4
-A3
J4
-A4
J2
-A1
J2
-A2
BN44 FUNCTIONENABLE
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
MODELS
WITHOUT
OUTRIGGERS
M4
J4
-C1
LP
GS
EL
EC
T
Q1
J4
-C2
FU
EL
PU
MP
M4
GA
SO
LIN
ES
EL
EC
T
Q2
Q1 Q2
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March 2005Section 6 • Schematics
REV B
6 - 24 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (from serial number 41200 to 41823)Part 3 of 3
PLATFORM CONTROLS
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT7
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
LPG LED L22
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW25DIPSWITCH
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
LPG SELECT BN14
HIGH TORQUE BN6PIN23
PIN24
PIN13
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
(GASOLINE/LPG MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT7
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
LPG LED L22
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
LPG SELECT/RR OUTRIGGER BN22
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM & OUTRIGGERUP/DOWN TS21
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(GASOLINE/LPG MODELS WITH OUTRIGGERS)
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 25
This page intentionally left blank.
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March 2005Section 6 • Schematics
REV A
6 - 26 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (from serial number 41824 to GS6803-42381)Part 1 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES0116V
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
87
30
85
86
G6
G6
CB120A
ENGINESTART
CR1
BA
TT
ER
Y1
2V
DC
B1 D1
D1
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3
IGNITIONCR8
ECMPOWER TOCR43
ENGINE RUNCR25
STARTING AIDCR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
()-
(+) B112V DC
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
OIL
PR
ES
SU
RE
SW
ITC
H
SW2
J4
-B2
SW2
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
SW1
J4
-B1
SW1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
Y10 Y10A
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
J1-C1\C4
BN68START
J4
-A2
L30
L30WO
RK
LIG
HT
S(O
PT
ION
)
EN
GIN
ES
TA
RT
ER
M3
M3 SP
AR
KP
LU
G(S
)
IGN
ITIO
NC
OIL
U19 DIS
TR
IBU
TO
R
U26
GU26
SP
AR
KP
LU
G(S
)
U20IGN
ITIO
NC
OIL
DIS
TR
IBU
TO
R
U19
CR
17
87
30
85
86
SW4
SW4
HY
DR
AU
LIC
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
M1
N.O.
F9A20A
HY
DR
AU
LIC
OIL
CO
OL
ING
FA
N(O
PT
ION
)
M1
HYDRAULICOIL COOLER
(OPTION)
CH
OK
E
Q7
Q7
J1
-A9
87a
PLATFORM
GROUND
GROUND
B
KS1KEY SWITCH
B1
2
4
3
![Page 191: Service Manual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · in this manual and the appropriate Operator's Manual on your machine will result in death](https://reader035.fdocuments.us/reader035/viewer/2022062413/5aad9e347f8b9adb688b4b95/html5/thumbnails/191.jpg)
March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 27
Electrical SchematicGasoline/LPG Models (from serial number 41824 to GS6803-42381)
Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES0116V
J3
-A1
J3
-A3
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
ELECTRONIC CONTROL MODULE
U5
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
(OPTION)
J3
-A2
N.C.
LS6PLATFORM
DOWN
P1EMERGENCY
STOP
BN90GLOWPLUG
TS54HIGHIDLE
BN83PLATFORM
UP
BN84PLATFORM
DOWN
J4
-A3
J4
-A4
J2
-A1
J2
-A2
BN44 FUNCTIONENABLE
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
MODELS
WITHOUT
OUTRIGGERS
M4
J4
-C1
LP
GS
EL
EC
T
Q1
J4
-C2
FU
EL
PU
MP
M4
GA
SO
LIN
ES
EL
EC
T
Q2
Q1 Q2
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March 2005Section 6 • Schematics
REV A
6 - 28 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicGasoline/LPG Models (from serial number 41824 to GS6803-42381)Part 3 of 3
PLATFORM CONTROLS
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT7
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
LPG LED L22
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
SW25DIPSWITCH
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
LPG SELECT BN14
HIGH TORQUE BN6PIN23
PIN24
PIN13
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
(GASOLINE/LPG MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT7
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
LPG LED L22
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
LPG SELECT/RR OUTRIGGER BN22
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM & OUTRIGGERUP/DOWN TS21
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(GASOLINE/LPG MODELS WITH OUTRIGGERS)
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 29
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March 2005Section 6 • Schematics
REV A
6 - 30 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicANSI Models with Gasoline/LPG Power(from serial number GS6803-42382 to GS6805-43594)Part 1 of 3
PLATFORMCONTROL
GROUNDCONTROL
CB2 20A
B1
12
VO
LTB
AT
TE
RY
J1
-C2
J2
-B8
J2
-B7
CR41CONTROLSYSTEM
P1EMERGENCY STOP
CR5HORN
CR42POWER
CR8IGNITION
CR1ENGINESTART
KS1 KEY SWITCH
J2
-B11
M3
STA
RT
ER
MO
TO
R
K1
STA
RT
ER
RE
LA
Y
-
+
B1
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
STARTER
M3
H2
H2
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
D1EXCT
D1
ALT
ER
NA
TO
R
B
B1
4
2
3
CR23AUXILIARYDOWN
J2
-A4
J2-C4
J2-B9
J1-C7
J2
-C1
/C3
J2
-A3
BN23AUXILIARY DOWN
BN91AUXILIARY DOWNENABLE
J2
-A5
U3
2G
LO
WP
LU
G(O
PT
ION
)
CR15STARTINGAID
Q3
HIG
HID
LE
SO
LE
NO
ID
CR4HIGH IDLE
Q3HIGH IDLESOLENOID
C54700 uF
LS6PLAT
DOWNLIMIT
SWITCH
J2
-A2
N.C.
L3
0W
OR
KL
IGH
TS
(OP
TIO
N)
BAT
STA
G6
EN
GIN
EH
OU
RM
ET
ER
G6HOUR
METER
Y8
PL
AT
FO
RM
UP
Y7
PL
AT
FO
RM
DO
WN
J1
-A3
Y7
Y1
0A
UX
PL
AT
FO
RM
DO
WN
Y7
AP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y1
0A
AU
XP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y10
Y7A Y10A
U5ECM
ES7161A
J1
-A9
J2
-C1
2
Y8
U2
0S
PA
RK
PL
UG
(S)
U2
6D
IST
RIB
UT
OR
U1
9IG
NIT
ION
CO
IL
G
U26
(+)
U19
()
-
Q7CHOKESOLENOID
AB1
AB7 AB3AB3
AB28
L30WORK LIGHTS
AB1
AB3
85
86 30
87 87A
6
85
86 30
87 87A
5
85
86 30
87 87A
4
85
86 30
87 87A
3
85
86 30
87 87A
2
85
86 30
87 87A
1
85
86 30
87 87A
8
85
86 30
87 87A
7
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 31
Electrical SchematicANSI Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
SW
1C
OO
LA
NT
TE
MP
ER
AT
UR
ES
WIT
CH
SW1
J1
-C9
SW
2O
ILP
RE
SS
UR
ES
WIT
CH
SW2
J1
-C8
U5ELECTRONIC CONTROL MODULE
FB
1F
LA
SH
ING
BE
AC
ON
(OP
TIO
N)
J2
-C11
FB1H5
H5
AL
AR
MJ2
-B1
2
Y2
9G
EN
ER
AT
OR
(OP
TIO
N)
J1
-B1
S7
LE
VE
LS
EN
SO
R
EC
MG
RO
UN
DJ2
-C7
Y2
J1
-A4
Y4
ST
EE
RL
EF
T
Y1
DR
IVE
PA
RA
LL
EL
Y2
BR
AK
ER
EL
EA
SE
Y3
ST
EE
RR
IGH
T
J1
-A2
Y3
Y4
J1
-A1
0
J1
-A11
Y1
J1
-A1
2
Y1B
J1
-A1
Y1A
J1
-A5
Y5
Y6
J1
-A7
J1
-A8
Y6A
J1
-B3
Y9
J1
-A6
Y5A
Y1
AD
RIV
EP
AR
AL
LE
L
Y1
BD
RIV
EP
AR
AL
LE
L
Y6
DR
IVE
FO
RW
AR
D(1
)
Y6
AD
RIV
EF
OR
WA
RD
(2)
Y5
DR
IVE
RE
VE
RS
E(1
)
Y5
AD
RIV
ER
EV
ER
SE
(2)
Y9
PR
OP
OR
TIO
NA
LF
LO
WC
ON
TR
OL
Y29
ES7161A
J1
-C11
Q2
Q2
GA
SO
LIN
ES
EL
EC
T
M4
M4
FU
EL
PU
MP
J1
-B1
2
Q1
Q1
LP
GS
EL
EC
T
BK
RD
WH
N.C.LEVEL SENSORCIRCUIT BOARD
MODELS WITHOUT
OUTRIGGERS
S7 LEVELSENSOR
J2
-B2
J2
-A6
J2
-B1
0
AB29
AB1
AB23
CR17
SW4
M1
N.O.F9A20A
85
8630
87
HYDRAULICOIL COOLER(OPTION)
BATTERY (-)
BATTERY (+)
CR8 TERMINAL 30 AB2
AB13AB11AB22
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March 2005Section 6 • Schematics
REV A
6 - 32 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicANSI Models with Gasoline/LPG Power(from serial number GS6803-42382 to GS6805-43594)Part 3 of 3
ES7161A
J1
-C3
J1
-C4
J1
-C6
LS14LR
O-RIGLIMIT
SWITCH
LS15RR
O-RIGLIMIT
SWITCH
LS13RF
O-RIGLIMIT
SWITCH
J1
-C5
N.O. N.O. N.O. N.O.
LS12LF
O-RIGLIMIT
SWITCH
OUTRIGGERS(OPTION)
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
U5ELECTRONIC
CONTROLMODULE
GN
DF
RO
MP
LA
TJ2
-A1
0
WH/RD
RD/WH
1BL
2BK
5OR
QD4
3
4
DA
TA
LIN
K(-)
DA
TA
LIN
K(+
)J2
-A11
J2
-A1
2
1
2
5
3
4
PLATFORM
CONTROLS
BK
RD
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
3 RD
4
WH1
BL2
OR5
QD3
D7VOLTAGE
REGULATOR5V DC
12V DC
J5 PIN2
3
4
1
2
5
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
J5 PIN5
J5 PIN4
J5 PIN1WH
BL
OR
JC1JOYSTICK
CONTROLLER
SW6STEERLEFT/ RIGHT
LE
FT
RIG
HT
SW5FUNCTION ENABLE
J2 PIN6
J2 PIN7
J2 PIN4
J2 PIN5
BK
RD
OR
PP
WH
BN
HALL EFFECTGENERATOR
GYJ2 PIN1
J2 PIN12
J2 PIN13
YLJ2 PIN2
J2 PIN3BL
WH/BLJ2 PIN8
H1ALARM
J3 PIN2
J3 PIN1RD +
BK
POUT1
PIN14
HORN BN5
ENGINE START BN2
PIN2
PIN3
PIN4
STARTING AID BN3
ORGR AUTOLEVEL ENABLE BN20
PIN7 LPG SELECT BN14
PIN6 GENERATOR BN7
PIN9 LF OUTRIGGER ENABLE BN85
PIN8 HIGH IDLE BN4
PIN11 LR OUTRIGGER ENABLE BN87
PIN10 RF OUTRIGGER ENABLE BN86
PIN13 LIFT FUNCTION BN9
PIN12 RR OUTRIGGER ENABLE BN24
PIN5 HIGH TORQUE BN6
PIN15 SYSTEM STATUS L50
GYJ5 PIN3
J2 PIN14
BL
RD
BK
YLJ1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
PLATFORM UP/DOWN TS20-OR-
PLATFORM & OUTRIGGERUP/DOWN
TS21
EMERGENCYSTOP
P2
Y36 Y34
Y35 Y33
J1
-B11
J1
-B9
J1
-B5
Y3
4R
IGH
TR
EA
RO
UT
RIG
GE
R
Y3
5L
EF
TF
RO
NT
OU
TR
IGG
ER
Y3
6R
IGH
TF
RO
NT
OU
TR
IGG
ER
J1
-B1
0Y
33
LE
FT
RE
AR
OU
TR
IGG
ER
Y4
0O
UT
RIG
GE
RE
XT
EN
D
Y3
9O
UT
RIG
GE
RR
ET
RA
CT
S8
2-A
XIS
LE
VE
LS
EN
SO
R
Y40 Y44
J1
-B8
J1
-B6
Y39
J1
-B7
Y4
4O
UT
RIG
GE
RD
OW
NS
LO
W
AB3 AB3 AB2 AB2
AB16AB17AB26AB27
AB9 AB15 AB8 AB6
AB10 AB14 AB7
S82 AXIS
TILT LEVELSENSOR
J2
-B1
0R
DP
OW
ER
J2
-B3
YL
RO
LL
J2
-B1
BL
PIT
CH
J2
-B2
BK
GR
OU
ND
AB1AB25
AB24AB23
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 33
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March 2005Section 6 • Schematics
REV A
6 - 34 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicANSI Models with Gasoline/LPG Power(after serial number GS6805-43594)Part 1 of 3
CB2 20A
B1
12
VO
LTB
AT
TE
RY
J1
-C2
J2
-B8
J2
-B7
CR41CONTROLSYSTEM
CR5HORN
CR42POWER
CR8IGNITION
CR1ENGINESTART
J2
-B11
M3
STA
RT
ER
MO
TO
R
K1
STA
RT
ER
RE
LA
Y
-
+
B1
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
STARTER
M3
H2
H2
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
D1EXCT
D1
ALT
ER
NA
TO
R
CR23AUXILIARYDOWN
J2
-A4
J2-C4
J2-B9
J1-C7
J2
-C1
/C3
J2
-A3
BN23AUXILIARY DOWN
BN91AUXILIARY DOWNENABLE
J2
-A5
U3
2G
LO
WP
LU
G(O
PT
ION
)
CR15STARTINGAID
Q3
HIG
HID
LE
SO
LE
NO
ID
CR4HIGH IDLE
Q3HIGH IDLESOLENOID
C54700 uF
LS6PLAT
DOWNLIMIT
SWITCH
J2
-A2
N.C.
L3
0W
OR
KL
IGH
TS
(OP
TIO
N)
BAT
STA
G6
EN
GIN
EH
OU
RM
ET
ER
G6HOUR
METER
Y8
PL
AT
FO
RM
UP
Y7
PL
AT
FO
RM
DO
WN
J1
-A3
Y7
Y1
0A
UX
PL
AT
FO
RM
DO
WN
Y7
AP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y1
0A
AU
XP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y10
Y7A Y10A
U5ECM
ES7161D
J1
-A9
J2
-C1
2
Y8
U2
0S
PA
RK
PL
UG
(S)
U2
6D
IST
RIB
UT
OR
U1
9IG
NIT
ION
CO
IL
G
U26
(+)
U19
()
-
Q7CHOKESOLENOID
AB1
AB7 AB3AB3
AB28
L30WORK LIGHTS
AB1
AB3
P1EMERGENCY STOPF9 5A FUSE
PLATFORMCONTROL
GROUNDCONTROL
B
B1
4
2
3
KS1 KEY SWITCH
85
86 30
87 87A
6
85
86 30
87 87A
5
85
86 30
87 87A
4
85
86 30
87 87A
3
85
86 30
87 87A
2
85
86 30
87 87A
1
85
86 30
87 87A
8
85
86 30
87 87A
7
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 35
Electrical SchematicANSI Models with Gasoline/LPG Power
(after serial number GS6805-43594)Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
SW
1C
OO
LA
NT
TE
MP
ER
AT
UR
ES
WIT
CH
SW1
J1
-C9
SW
2O
ILP
RE
SS
UR
ES
WIT
CH
SW2
J1
-C8
U5ELECTRONIC CONTROL MODULE
FB
1F
LA
SH
ING
BE
AC
ON
(OP
TIO
N)
J2
-C11
FB1H5
H5
AL
AR
MJ2
-B1
2
Y2
9G
EN
ER
AT
OR
(OP
TIO
N)
J1
-B1
S7
LE
VE
LS
EN
SO
R
EC
MG
RO
UN
DJ2
-C7
Y2
J1
-A4
Y4
ST
EE
RL
EF
T
Y1
DR
IVE
PA
RA
LL
EL
Y2
BR
AK
ER
EL
EA
SE
Y3
ST
EE
RR
IGH
T
J1
-A2
Y3
Y4
J1
-A1
0
J1
-A11
Y1
J1
-A1
2
Y1B
J1
-A1
Y1A
J1
-A5
Y5
Y6
J1
-A7
J1
-A8
Y6A
J1
-B3
Y9
J1
-A6
Y5A
Y1
AD
RIV
EP
AR
AL
LE
L
Y1
BD
RIV
EP
AR
AL
LE
L
Y6
DR
IVE
FO
RW
AR
D(1
)
Y6
AD
RIV
EF
OR
WA
RD
(2)
Y5
DR
IVE
RE
VE
RS
E(1
)
Y5
AD
RIV
ER
EV
ER
SE
(2)
Y9
PR
OP
OR
TIO
NA
LF
LO
WC
ON
TR
OL
Y29
ES7161D
J1
-C11
Q2
Q2
GA
SO
LIN
ES
EL
EC
T
M4
M4
FU
EL
PU
MP
J1
-B1
2
Q1
Q1
LP
GS
EL
EC
T
BK
RD
WH
N.C.LEVEL SENSORCIRCUIT BOARD
MODELS WITHOUT
OUTRIGGERS
S7 LEVELSENSOR
J2
-B2
J2
-A6
J2
-B1
0
AB29
AB1
AB23
CR17
SW4
M1
N.O.F9A20A
85
8630
87
HYDRAULICOIL COOLER(OPTION)
BATTERY (-)
BATTERY (+)
CR8 TERMINAL 30 AB2
AB13AB11AB22
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March 2005Section 6 • Schematics
REV A
6 - 36 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicANSI Models with Gasoline/LPG Power(after serial number GS6805-43594)Part 3 of 3
ES7161D
J1
-C3
J1
-C4
J1
-C6
LS14LR
O-RIGLIMIT
SWITCH
LS15RR
O-RIGLIMIT
SWITCH
LS13RF
O-RIGLIMIT
SWITCH
J1
-C5
N.O. N.O. N.O. N.O.
LS12LF
O-RIGLIMIT
SWITCH
OUTRIGGERS(OPTION)
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
U5ELECTRONIC
CONTROLMODULE
GN
DF
RO
MP
LA
TJ2
-A1
0
WH/RD
RD/WH
1BL
2BK
5OR
QD4
3
4
DA
TA
LIN
K(-)
DA
TA
LIN
K(+
)J2
-A11
J2
-A1
2
1
2
5
3
4
PLATFORM
CONTROLS
BK
RD
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
3 RD
4
WH1
BL2
OR5
QD3
D7VOLTAGE
REGULATOR5V DC
12V DC
J5 PIN2
3
4
1
2
5
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
J5 PIN5
J5 PIN4
J5 PIN1WH
BL
OR
JC1JOYSTICK
CONTROLLER
SW6STEERLEFT/ RIGHT
LE
FT
RIG
HT
SW5FUNCTION ENABLE
J2 PIN6
J2 PIN7
J2 PIN4
J2 PIN5
BK
RD
OR
PP
WH
BN
HALL EFFECTGENERATOR
GYJ2 PIN1
J2 PIN12
J2 PIN13
YLJ2 PIN2
J2 PIN3BL
WH/BLJ2 PIN8
H1ALARM
J3 PIN2
J3 PIN1RD +
BK
POUT1
PIN14
HORN BN5
ENGINE START BN2
PIN2
PIN3
PIN4
STARTING AID BN3
ORGR AUTOLEVEL ENABLE BN20
PIN7 LPG SELECT BN14
PIN6 GENERATOR BN7
PIN9 LF OUTRIGGER ENABLE BN85
PIN8 HIGH IDLE BN4
PIN11 LR OUTRIGGER ENABLE BN87
PIN10 RF OUTRIGGER ENABLE BN86
PIN13 LIFT FUNCTION BN9
PIN12 RR OUTRIGGER ENABLE BN24
PIN5 HIGH TORQUE BN6
PIN15 SYSTEM STATUS L50
GYJ5 PIN3
J2 PIN14
BL
RD
BK
YLJ1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
PLATFORM UP/DOWN TS20-OR-
PLATFORM & OUTRIGGERUP/DOWN
TS21
EMERGENCYSTOP
P2
Y36 Y34
Y35 Y33
J1
-B11
J1
-B9
J1
-B5
Y3
4R
IGH
TR
EA
RO
UT
RIG
GE
R
Y3
5L
EF
TF
RO
NT
OU
TR
IGG
ER
Y3
6R
IGH
TF
RO
NT
OU
TR
IGG
ER
J1
-B1
0Y
33
LE
FT
RE
AR
OU
TR
IGG
ER
Y4
0O
UT
RIG
GE
RE
XT
EN
D
Y3
9O
UT
RIG
GE
RR
ET
RA
CT
S8
2-A
XIS
LE
VE
LS
EN
SO
R
Y40 Y44
J1
-B8
J1
-B6
Y39
J1
-B7
Y4
4O
UT
RIG
GE
RD
OW
NS
LO
W
AB3 AB3 AB2 AB2
AB16AB17AB26AB27
AB9 AB15 AB8 AB6
AB10 AB14 AB7
S82 AXIS
TILT LEVELSENSOR
J2
-B1
0R
DP
OW
ER
J2
-B3
YL
RO
LL
J2
-B1
BL
PIT
CH
J2
-B2
BK
GR
OU
ND
AB1AB25
AB24AB23
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 37
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March 2005Section 6 • Schematics
REV A
6 - 38 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicCE Models with Gasoline/LPG Power(from serial number GS6803-42382 to GS6805-43594)Part 1 of 3
PLATFORMCONTROL
GROUNDCONTROL
CB2 20A
B1
12
VO
LTB
AT
TE
RY
J1
-C2
J2
-B8
J2
-B7
CR41CONTROLSYSTEM
P1EMERGENCY STOP
CR5HORN
CR42POWER
CR8IGNITION
CR1ENGINESTART
KS1 KEY SWITCH
J2
-B11
M3
STA
RT
ER
MO
TO
R
K1
STA
RT
ER
RE
LA
Y
-
+
B1
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
STARTER
M3
H2
H2
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
D1EXCT
D1
ALT
ER
NA
TO
R
B
B1
4
2
3
CR23AUXILIARYDOWN
J2
-A4
J2-C4
J1-C7
J2
-C1
/C3
J2
-A3
BN23AUXILIARY DOWN
BN91AUXILIARY DOWNENABLE
J2
-A5
U3
2G
LO
WP
LU
G(O
PT
ION
)
CR15STARTINGAID
LS6PLAT
DOWNLIMIT
SWITCH
J2
-A2
N.C.
BAT
STA
G6HOUR
METER
U5ECM
ES7161A
J2
-C1
2
U2
0S
PA
RK
PL
UG
(S)
U2
6D
IST
RIB
UT
OR
U1
9IG
NIT
ION
CO
IL
G
U26
(+)
U19
()
-
Q7CHOKESOLENOID
AB1
AB4
AB28
AB1
AB3
J2-B9
Q3
HIG
HID
LE
SO
LE
NO
ID
CR4HIGH IDLE
Q3HIGH IDLESOLENOID
C54700 uF
L30WORKLIGHTS
L3
0W
OR
KL
IGH
TS
(OP
TIO
N)
G6
EN
GIN
EH
OU
RM
ET
ER
J1
-A9
J1
-A3
Y8
PL
AT
FO
RM
UP
Y8
Y7
PL
AT
FO
RM
DO
WN
LS25LOAD SENSEDELAYLIMIT SW
N.C.
CR77DOWN
ENABLE
87A85
86 30
87
9
LS24MAXIMUMHEIGHTLIMIT SW
N.C.
Y7
Y1
0A
UX
PL
AT
FO
RM
DO
WN
Y7
AP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y1
0A
AU
XP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y10
Y7A Y10A
AB12
PS2PLATFORMOVERLOADPRESSURE
SWITCH
AB7
AB20
AB21
AB1
AB1
85
86 30
87 87A
6
85
86 30
87 87A
5
85
86 30
87 87A
4
85
86 30
87 87A
3
85
86 30
87 87A
2
85
86 30
87 87A
1
85
86 30
87 87A
8
85
86 30
87 87A
7
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 39
Electrical SchematicCE Models with Gasoline/LPG Power
(from serial number GS6803-42382 to GS6805-43594)Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
SW
1C
OO
LA
NT
TE
MP
ER
AT
UR
ES
WIT
CH
SW1
J1
-C9
SW
2O
ILP
RE
SS
UR
ES
WIT
CH
SW2
J1
-C8
U5ELECTRONIC CONTROL MODULE
FB
1F
LA
SH
ING
BE
AC
ON
(OP
TIO
N)
J2
-C11
FB1H5
H5
AL
AR
MJ2
-B1
2
Y2
9G
EN
ER
AT
OR
(OP
TIO
N)
J1
-B1
S7
LE
VE
LS
EN
SO
R
EC
MG
RO
UN
DJ2
-C7
Y2
J1
-A4
Y4
ST
EE
RL
EF
T
Y1
DR
IVE
PA
RA
LL
EL
Y2
BR
AK
ER
EL
EA
SE
Y3
ST
EE
RR
IGH
T
J1
-A2
Y3
Y4
J1
-A1
0
J1
-A11
Y1
J1
-A1
2
Y1B
J1
-A1
Y1A
J1
-A5
Y5
Y6
J1
-A7
J1
-A8
Y6A
J1
-B3
Y9
J1
-A6
Y5A
Y1
AD
RIV
EP
AR
AL
LE
L
Y1
BD
RIV
EP
AR
AL
LE
L
Y6
DR
IVE
FO
RW
AR
D(1
)
Y6
AD
RIV
EF
OR
WA
RD
(2)
Y5
DR
IVE
RE
VE
RS
E(1
)
Y5
AD
RIV
ER
EV
ER
SE
(2)
Y9
PR
OP
OR
TIO
NA
LF
LO
WC
ON
TR
OL
Y29
ES7161A
J1
-C11
Q2
Q2
GA
SO
LIN
ES
EL
EC
T
M4
M4
FU
EL
PU
MP
J1
-B1
2
Q1
Q1
LP
GS
EL
EC
T
BK
RD
WH
N.C.LEVEL SENSORCIRCUIT BOARD
MODELS WITHOUT
OUTRIGGERS
S7 LEVELSENSOR
J2
-B2
J2
-A6
J2
-B1
0
AB29
AB1
AB23
CR17
SW4
M1
N.O.F9A20A
85
8630
87
HYDRAULICOIL COOLER(OPTION)
BATTERY (-)
BATTERY (+)
CR8 TERMINAL 30 AB2
AB13AB11AB22
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March 2005Section 6 • Schematics
REV A
6 - 40 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicCE Models with Gasoline/LPG Power(from serial number GS6803-42382 to GS6805-43594)Part 3 of 3
ES7161A
J1
-C3
J1
-C4
J1
-C6
LS14LR
O-RIGLIMIT
SWITCH
LS15RR
O-RIGLIMIT
SWITCH
LS13RF
O-RIGLIMIT
SWITCH
J1
-C5
N.O. N.O. N.O. N.O.
LS12LF
O-RIGLIMIT
SWITCH
OUTRIGGERS(OPTION)
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
U5ELECTRONIC
CONTROLMODULE
GN
DF
RO
MP
LA
TJ2
-A1
0
WH/RD
RD/WH
1BL
2BK
5OR
QD4
3
4
DA
TA
LIN
K(-)
DA
TA
LIN
K(+
)J2
-A11
J2
-A1
2
1
2
5
3
4
PLATFORM
CONTROLS
BK
RD
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
3 RD
4
WH1
BL2
OR5
QD3
D7VOLTAGE
REGULATOR5V DC
12V DC
J5 PIN2
3
4
1
2
5
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
J5 PIN5
J5 PIN4
J5 PIN1WH
BL
OR
JC1JOYSTICK
CONTROLLER
SW6STEERLEFT/ RIGHT
LE
FT
RIG
HT
SW5FUNCTION ENABLE
J2 PIN6
J2 PIN7
J2 PIN4
J2 PIN5
BK
RD
OR
PP
WH
BN
HALL EFFECTGENERATOR
GYJ2 PIN1
J2 PIN12
J2 PIN13
YLJ2 PIN2
J2 PIN3BL
WH/BLJ2 PIN8
H1ALARM
J3 PIN2
J3 PIN1RD +
BK
POUT1
PIN14
HORN BN5
ENGINE START BN2
PIN2
PIN3
PIN4
STARTING AID BN3
ORGR AUTOLEVEL ENABLE BN20
PIN7 LPG SELECT BN14
PIN6 GENERATOR BN7
PIN9 LF OUTRIGGER ENABLE BN85
PIN8 HIGH IDLE BN4
PIN11 LR OUTRIGGER ENABLE BN87
PIN10 RF OUTRIGGER ENABLE BN86
PIN13 LIFT FUNCTION BN9
PIN12 RR OUTRIGGER ENABLE BN24
PIN5 HIGH TORQUE BN6
PIN15 SYSTEM STATUS L50
GYJ5 PIN3
J2 PIN14
BL
RD
BK
YLJ1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
PLATFORM UP/DOWN TS20-OR-
PLATFORM & OUTRIGGERUP/DOWN
TS21
EMERGENCYSTOP
P2
Y36 Y34
Y35 Y33
J1
-B11
J1
-B9
J1
-B5
Y3
4R
IGH
TR
EA
RO
UT
RIG
GE
R
Y3
5L
EF
TF
RO
NT
OU
TR
IGG
ER
Y3
6R
IGH
TF
RO
NT
OU
TR
IGG
ER
J1
-B1
0Y
33
LE
FT
RE
AR
OU
TR
IGG
ER
Y4
0O
UT
RIG
GE
RE
XT
EN
D
Y3
9O
UT
RIG
GE
RR
ET
RA
CT
S8
2-A
XIS
LE
VE
LS
EN
SO
R
Y40 Y44
J1
-B8
J1
-B6
Y39
J1
-B7
Y4
4O
UT
RIG
GE
RD
OW
NS
LO
W
AB3 AB3 AB2 AB2
AB16AB17AB26AB27
AB9 AB15 AB8 AB6
AB10 AB14 AB7
S82 AXIS
TILT LEVELSENSOR
J2
-B1
0R
DP
OW
ER
J2
-B3
YL
RO
LL
J2
-B1
BL
PIT
CH
J2
-B2
BK
GR
OU
ND
AB1AB25
AB24AB23
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 41
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March 2005Section 6 • Schematics
REV A
6 - 42 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicCE Models with Gasoline/LPG Power(after serial number GS6805-43594)Part 1 of 3
CB2 20A
B1
12
VO
LTB
AT
TE
RY
J1
-C2
J2
-B8
J2
-B7
CR41CONTROLSYSTEM
CR5HORN
CR42POWER
CR8IGNITION
CR1ENGINESTART
J2
-B11
M3
STA
RT
ER
MO
TO
R
K1
STA
RT
ER
RE
LA
Y
-
+
B1
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
STARTER
M3
H2
H2
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
D1EXCT
D1
ALT
ER
NA
TO
R
CR23AUXILIARYDOWN
J2
-A4
J2-C4
J1-C7
J2
-C1
/C3
J2
-A3
BN23AUXILIARY DOWN
BN91AUXILIARY DOWNENABLE
J2
-A5
U3
2G
LO
WP
LU
G(O
PT
ION
)
CR15STARTINGAID
LS6PLAT
DOWNLIMIT
SWITCH
J2
-A2
N.C.
BAT
STA
G6HOUR
METER
U5ECM
ES7183B
J2
-C1
2
U2
0S
PA
RK
PL
UG
(S)
U2
6D
IST
RIB
UT
OR
U1
9IG
NIT
ION
CO
IL
G
U26
(+)
U19
()
-
Q7CHOKESOLENOID
AB1
AB4
AB28
AB1
AB3
J2-B9
Q3
HIG
HID
LE
SO
LE
NO
ID
CR4HIGH IDLE
Q3HIGH IDLESOLENOID
C54700 uF
L30WORKLIGHTS
L3
0W
OR
KL
IGH
TS
(OP
TIO
N)
G6
EN
GIN
EH
OU
RM
ET
ER
J1
-A9
J1
-A3
Y8
PL
AT
FO
RM
UP
Y8
Y7
PL
AT
FO
RM
DO
WN
LS25LOAD SENSEDELAYLIMIT SW
N.C.
CR77DOWN
ENABLE
87A85
86 30
87
9
LS24MAXIMUMHEIGHTLIMIT SW
N.C.
Y7
Y1
0A
UX
PL
AT
FO
RM
DO
WN
Y7
AP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y1
0A
AU
XP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y10
Y7A Y10A
AB12
PS2PLATFORMOVERLOADPRESSURE
SWITCH
AB7
AB20
AB21
AB1
AB1
P1EMERGENCY STOPF9 5A FUSE
PLATFORMCONTROL
GROUNDCONTROL
B
B1
4
2
3
KS1 KEY SWITCH
85
86 30
87 87A
6
85
86 30
87 87A
5
85
86 30
87 87A
4
85
86 30
87 87A
3
85
86 30
87 87A
2
85
86 30
87 87A
1
85
86 30
87 87A
8
85
86 30
87 87A
7
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 43
Electrical SchematicCE Models with Gasoline/LPG Power(after serial number GS6805-43594)
Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
SW
1C
OO
LA
NT
TE
MP
ER
AT
UR
ES
WIT
CH
SW1
J1
-C9
SW
2O
ILP
RE
SS
UR
ES
WIT
CH
SW2
J1
-C8
U5ELECTRONIC CONTROL MODULE
FB
1F
LA
SH
ING
BE
AC
ON
(OP
TIO
N)
J2
-C11
FB1H5
H5
AL
AR
MJ2
-B1
2
Y2
9G
EN
ER
AT
OR
(OP
TIO
N)
J1
-B1
S7
LE
VE
LS
EN
SO
R
EC
MG
RO
UN
DJ2
-C7
Y2
J1
-A4
Y4
ST
EE
RL
EF
T
Y1
DR
IVE
PA
RA
LL
EL
Y2
BR
AK
ER
EL
EA
SE
Y3
ST
EE
RR
IGH
T
J1
-A2
Y3
Y4
J1
-A1
0
J1
-A11
Y1
J1
-A1
2
Y1B
J1
-A1
Y1A
J1
-A5
Y5
Y6
J1
-A7
J1
-A8
Y6A
J1
-B3
Y9
J1
-A6
Y5A
Y1
AD
RIV
EP
AR
AL
LE
L
Y1
BD
RIV
EP
AR
AL
LE
L
Y6
DR
IVE
FO
RW
AR
D(1
)
Y6
AD
RIV
EF
OR
WA
RD
(2)
Y5
DR
IVE
RE
VE
RS
E(1
)
Y5
AD
RIV
ER
EV
ER
SE
(2)
Y9
PR
OP
OR
TIO
NA
LF
LO
WC
ON
TR
OL
Y29
ES7183B
J1
-C11
Q2
Q2
GA
SO
LIN
ES
EL
EC
T
M4
M4
FU
EL
PU
MP
J1
-B1
2
Q1
Q1
LP
GS
EL
EC
T
BK
RD
WH
N.C.LEVEL SENSORCIRCUIT BOARD
MODELS WITHOUT
OUTRIGGERS
S7 LEVELSENSOR
J2
-B2
J2
-A6
J2
-B1
0
AB29
AB1
AB23
CR17
SW4
M1
N.O.F9A20A
85
8630
87
HYDRAULICOIL COOLER(OPTION)
BATTERY (-)
BATTERY (+)
CR8 TERMINAL 30 AB2
AB13AB11AB22
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March 2005Section 6 • Schematics
REV A
6 - 44 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicCE Models with Gasoline/LPG Power(after serial number GS6805-43594)Part 3 of 3
ES7183B
J1
-C3
J1
-C4
J1
-C6
LS14LR
O-RIGLIMIT
SWITCH
LS15RR
O-RIGLIMIT
SWITCH
LS13RF
O-RIGLIMIT
SWITCH
J1
-C5
N.O. N.O. N.O. N.O.
LS12LF
O-RIGLIMIT
SWITCH
OUTRIGGERS(OPTION)
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
U5ELECTRONIC
CONTROLMODULE
GN
DF
RO
MP
LA
TJ2
-A1
0
WH/RD
RD/WH
1BL
2BK
5OR
QD4
3
4
DA
TA
LIN
K(-)
DA
TA
LIN
K(+
)J2
-A11
J2
-A1
2
1
2
5
3
4
PLATFORM
CONTROLS
BK
RD
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
3 RD
4
WH1
BL2
OR5
QD3
D7VOLTAGE
REGULATOR5V DC
12V DC
J5 PIN2
3
4
1
2
5
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
J5 PIN5
J5 PIN4
J5 PIN1WH
BL
OR
JC1JOYSTICK
CONTROLLER
SW6STEERLEFT/ RIGHT
LE
FT
RIG
HT
SW5FUNCTION ENABLE
J2 PIN6
J2 PIN7
J2 PIN4
J2 PIN5
BK
RD
OR
PP
WH
BN
HALL EFFECTGENERATOR
GYJ2 PIN1
J2 PIN12
J2 PIN13
YLJ2 PIN2
J2 PIN3BL
WH/BLJ2 PIN8
H1ALARM
J3 PIN2
J3 PIN1RD +
BK
POUT1
PIN14
HORN BN5
ENGINE START BN2
PIN2
PIN3
PIN4
STARTING AID BN3
ORGR AUTOLEVEL ENABLE BN20
PIN7 LPG SELECT BN14
PIN6 GENERATOR BN7
PIN9 LF OUTRIGGER ENABLE BN85
PIN8 HIGH IDLE BN4
PIN11 LR OUTRIGGER ENABLE BN87
PIN10 RF OUTRIGGER ENABLE BN86
PIN13 LIFT FUNCTION BN9
PIN12 RR OUTRIGGER ENABLE BN24
PIN5 HIGH TORQUE BN6
PIN15 SYSTEM STATUS L50
GYJ5 PIN3
J2 PIN14
BL
RD
BK
YLJ1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
PLATFORM UP/DOWN TS20-OR-
PLATFORM & OUTRIGGERUP/DOWN
TS21
EMERGENCYSTOP
P2
Y36 Y34
Y35 Y33
J1
-B11
J1
-B9
J1
-B5
Y3
4R
IGH
TR
EA
RO
UT
RIG
GE
R
Y3
5L
EF
TF
RO
NT
OU
TR
IGG
ER
Y3
6R
IGH
TF
RO
NT
OU
TR
IGG
ER
J1
-B1
0Y
33
LE
FT
RE
AR
OU
TR
IGG
ER
Y4
0O
UT
RIG
GE
RE
XT
EN
D
Y3
9O
UT
RIG
GE
RR
ET
RA
CT
S8
2-A
XIS
LE
VE
LS
EN
SO
R
Y40 Y44
J1
-B8
J1
-B6
Y39
J1
-B7
Y4
4O
UT
RIG
GE
RD
OW
NS
LO
W
AB3 AB3 AB2 AB2
AB16AB17AB26AB27
AB9 AB15 AB8 AB6
AB10 AB14 AB7
S82 AXIS
TILT LEVELSENSOR
J2
-B1
0R
DP
OW
ER
J2
-B3
YL
RO
LL
J2
-B1
BL
PIT
CH
J2
-B2
BK
GR
OU
ND
AB1AB25
AB24AB23
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 45
This page intentionally left blank.
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March 2005Section 6 • Schematics
REV B
6 - 46 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (before serial number 21161)Part 1 of 2
EN
GIN
ES
TA
RT
ER
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
KS1PLATFORM
GROUND
87
30
85
86
G6
G6
TS54TS56TS52
CB2
1A
CB120A
33000 ufC2
ENGINESTART
CR1
AUXILIARYPLATFORMDOWN(GS-3268RT ONLY)
BN23
BA
TT
ER
Y1
2V
DC
B1 D1
D1
J4
-A3
GL
OW
PL
UG
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
J1
-C1
\C4
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
M3
M3
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3GL
OW
PL
UG
U32
U32
FUELCR8
ECMPOWER TOCR43
ENGINE RUNCR25
PLUGGLOWCR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
2000R7
()-
(+) B112V DC
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
(PU
LL
)
(HO
LD
)
Q8
FU
EL
SH
UT
OF
F
Q8
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES7140A
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
SW2
J4
-B2
SW2
J4
-B1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
OIL
PR
ES
SU
RE
SW
ITC
H
SW1
SW1
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 47
Electrical SchematicDiesel Models (before serial number 21161)
Part 2 of 2
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
TS67
DA
TA
LIN
K(-)
YL
J3
-A5
FUNCTIONENABLE
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
J3
-A2
J3
-A1
J3
-A3
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
G8
DISPLAYDIAGNOSTIC
N.C.N.C.
LS5PLATFORM
UP
LS6PLATFORM
DOWNJ1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7140A
ELECTRONIC CONTROL MODULE
U5
N.C.
LS1EXTENSION
DECK
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN9
PIN24
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
PP
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
OR
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS
PLATFORM EXT/RET ENABLE BN16PIN25
STARTING AID BN3PIN29
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March 2005Section 6 • Schematics
REV B
6 - 48 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 21161 to 21837)Part 1 of 2
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES7140B
EN
GIN
ES
TA
RT
ER
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
KS1PLATFORM
GROUND
87
30
85
86
G6
G6
TS54TS56TS52
CB2
1A
CB120A
ENGINESTART
CR1
AUXILIARYPLATFORMDOWN(GS-3268RT)
BN23
BA
TT
ER
Y1
2V
DC
B1 D1
D1
J4
-A3
GL
OW
PL
UG
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
J1
-C1
\C4
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
M3
M3
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3GL
OW
PL
UG
U32
U32
FUELCR8
ECMPOWER TOCR43
ENGINE RUNCR25
PLUGGLOWCR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
()-
(+) B112V DC
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
(PU
LL
)
(HO
LD
)
Q8
FU
EL
SH
UT
OF
F
Q8
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
OIL
PR
ES
SU
RE
SW
ITC
H
SW2
J4
-B2
SW2
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
SW1
J4
-B1
SW1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
33000 ufC2
2000R7
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 49
Electrical SchematicDiesel Models (from serial number 21161 to 21837)
Part 2 of 2
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7140B
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
ELECTRONIC CONTROL MODULE
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
TS67
DA
TA
LIN
K(-)
YL
J3
-A5
FUNCTIONENABLE
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
J3
-A2
J3
-A1
J3
-A3
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
G8
DISPLAYDIAGNOSTIC
N.C.N.C.
LS5PLATFORM
UP
LS6PLATFORM
DOWNJ1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
U5
N.C.
LS1EXTENSION
DECK
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN9
PIN24
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
PP
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
OR
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS
PLATFORM EXT/RET ENABLE BN16PIN25
STARTING AID BN3PIN29
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March 2005Section 6 • Schematics
REV B
6 - 50 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 21838 to 38464)Part 1 of 3
EN
GIN
ES
TA
RT
ER
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
KS1PLATFORM
GROUND
87
30
85
86
G6
G6
TS54TS56TS52
CB2
1A
CB120A
ENGINESTART
CR1
AUXILIARYPLATFORMDOWN(GS-3268RT)
BN23
BA
TT
ER
Y1
2V
DC
B1 D1
D1
J4
-A3
GL
OW
PL
UG
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
M3
M3
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3GL
OW
PL
UG
U32
U32
FUELCR8
ECMPOWER TOCR43
ENGINE RUNCR25
PLUGGLOWCR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
()-
(+) B112V DC
(PU
LL
)
(HO
LD
)
Q8
FU
EL
SH
UT
OF
F
Q8
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES7140C
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
OIL
PR
ES
SU
RE
SW
ITC
H
SW2
J4
-B2
SW2
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
SW1
J4
-B1
SW1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
F930A
F9 ADDED AFTER
SERIAL NUMBER 38365
F9
FU
SE
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
J1-C1\C4
33000 ufC2
2000R7
CB2 CHANGED TO 7 AMP
AFTER SERIAL NUMBER 33850
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 51
Electrical SchematicDiesel Models (from serial number 21838 to 38464)
Part 2 of 3
TS67FUNCTIONENABLE
J3
-A2
J3
-A1
J3
-A3
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
N.C.N.C.
LS5PLATFORM
UP
LS6PLATFORM
DOWN
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7140C
ELECTRONIC CONTROL MODULE
U5
NOTE: LS5, LS1USED ON
GS-3268AFTER SERIALNUMBER 26562
ONLY
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
N.C.
LS1EXTENSION
DECK
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
(OPTION)
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
MODELS
WITHOUT
OUTRIGGERS
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March 2005Section 6 • Schematics
REV B
6 - 52 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 21838 to 38464)Part 3 of 3
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN23
PIN24
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
RR OUTRIGGER BN24
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITH OUTRIGGERS)
PLATFORM & OUTRIGGERUP/DOWN TS21
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 53
This page intentionally left blank.
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March 2005Section 6 • Schematics
REV B
6 - 54 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 38465 to 40173)Part 1 of 3
EN
GIN
ES
TA
RT
ER
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
KS1PLATFORM
GROUND
87
30
85
86
G6
G6
TS54TS56TS52
CB2
7A
CB120A
ENGINESTART
CR1AUXILIARYPLATFORMDOWN(GS-3268RT)
BN23
BA
TT
ER
Y1
2V
DC
B1 D1
D1
J4
-A3
GL
OW
PL
UG
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
M3
M3
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3GL
OW
PL
UG
U32
U32
FUELCR8
ECMPOWER TOCR43
ENGINE RUNCR25
PLUGGLOWCR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
()-
(+) B112V DC
(PU
LL
)
(HO
LD
)
Q8
FU
EL
SH
UT
OF
F
Q8
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES7140H
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
OIL
PR
ES
SU
RE
SW
ITC
H
SW2
J4
-B2
SW2
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
SW1
J4
-B1
SW1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
F930A
F9
FU
SE
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
Y10 Y10A
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
J1-C1\C4
33000 ufC2
2000R7
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 55
Electrical SchematicDiesel Models (from serial number 38465 to 40173)
Part 2 of 3
TS67FUNCTIONENABLE
J3
-A2
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
N.C.
LS6PLATFORM
DOWN
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7140H
ELECTRONIC CONTROL MODULE
U5
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
J3
-A1
J3
-A3
N.C.
LS5PLATFORM
UP
GS-3268 ONLY
N.C.
LS1EXTENSION
DECK
(OPTION)
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
MODELS
WITHOUT
OUTRIGGERS
![Page 220: Service Manual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · in this manual and the appropriate Operator's Manual on your machine will result in death](https://reader035.fdocuments.us/reader035/viewer/2022062413/5aad9e347f8b9adb688b4b95/html5/thumbnails/220.jpg)
March 2005Section 6 • Schematics
REV B
6 - 56 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 38465 to 40173)Part 3 of 3
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN23
PIN24
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
RR OUTRIGGER BN24
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITH OUTRIGGERS)
PLATFORM & OUTRIGGERUP/DOWN TS21
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 57
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March 2005Section 6 • Schematics
REV B
6 - 58 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 40174 to 40939)Part 1 of 3
EN
GIN
ES
TA
RT
ER
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
KS1PLATFORM
GROUND
87
30
85
86
G6
G6
TS54TS56TS52
CB2
7A
CB120A
33000 ufC2
ENGINESTART
CR1AUXILIARYPLATFORMDOWN(GS-3268RT)
BN23
BA
TT
ER
Y1
2V
DC
B1 D1
D1
J4
-A3
GL
OW
PL
UG
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
M3
M3
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3GL
OW
PL
UG
U32
U32
FUELCR8
ECMPOWER TOCR43
ENGINE RUNCR25
PLUGGLOWCR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
2000R7
()-
(+) B112V DC
(PU
LL
)
(HO
LD
)
Q8
FU
EL
SH
UT
OF
F
Q8
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES7140
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
OIL
PR
ES
SU
RE
SW
ITC
H
SW2
J4
-B2
SW2
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
SW1
J4
-B1
SW1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
F930A
F9
FU
SE
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
Y10 Y10A
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
J1-C1\C4L30
L30WO
RK
LIG
HT
S(O
PT
ION
)
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 59
Electrical SchematicDiesel Models (from serial number 40174 to 40939)
Part 2 of 3
TS67FUNCTIONENABLE
J3
-A2
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
N.C.
LS6PLATFORM
DOWN
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7140
ELECTRONIC CONTROL MODULE
U5
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
J3
-A1
J3
-A3
N.C.
LS5PLATFORM
UP
GS-3268 ONLY
N.C.
LS1EXTENSION
DECK
(OPTION)
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
MODELS
WITHOUT
OUTRIGGERS
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March 2005Section 6 • Schematics
REV B
6 - 60 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 40174 to 40939)Part 3 of 3
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN23
PIN24
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
RR OUTRIGGER BN24
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITH OUTRIGGERS)
PLATFORM & OUTRIGGERUP/DOWN TS21
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 61
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March 2005Section 6 • Schematics
REV B
6 - 62 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 40940 to 41199)Part 1 of 3
EN
GIN
ES
TA
RT
ER
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
KS1PLATFORM
GROUND
87
30
85
86
G6
G6
TS54TS56TS52
CB2
7A
CB120A
33000 ufC2
ENGINESTART
CR1AUXILIARYPLATFORMDOWN(GS-3268RT)
BN23
BA
TT
ER
Y1
2V
DC
B1 D1
D1
J4
-A3
GL
OW
PL
UG
STA
RT
J4
-A2
J4
-A4
HIG
HID
LE
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
M3
M3
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3GL
OW
PL
UG
U32
U32
FUELCR8
ECMPOWER TOCR43
ENGINE RUNCR25
PLUGGLOWCR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
P1EMERGENCY
STOP
2000R7
()-
(+) B112V DC
(PU
LL
)
(HO
LD
)
Q8
FU
EL
SH
UT
OF
F
Q8
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES7140N
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
OIL
PR
ES
SU
RE
SW
ITC
H
SW2
J4
-B2
SW2
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
SW1
J4
-B1
SW1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
F930A
F9
FU
SE
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
Y10 Y10A
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
J1-C1\C4L30
L30WO
RK
LIG
HT
S(O
PT
ION
)
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 63
Electrical SchematicDiesel Models (from serial number 40940 to 41199)
Part 2 of 3
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
TS67FUNCTIONENABLE
J3
-A2
J3
-A1
J3
-A3
J2
-A1
J2
-A2
PL
AT
FO
RM
TS66
UP
DO
WN
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
N.C.N.C.
LS5PLATFORM
UP
LS6PLATFORM
DOWN
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7140N
ELECTRONIC CONTROL MODULE
U5
GS-3268 ONLY
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
N.C.
LS1EXTENSION
DECK
(OPTION)
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
MODELS
WITHOUT
OUTRIGGERS
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March 2005Section 6 • Schematics
REV B
6 - 64 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 40940 to 41199)Part 3 of 3
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN23
PIN24
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
RR OUTRIGGER BN24
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITH OUTRIGGERS)
PLATFORM & OUTRIGGERUP/DOWN TS21
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 65
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March 2005Section 6 • Schematics
REV B
6 - 66 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 41200 to 41823)Part 1 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES7140P
EN
GIN
ES
TA
RT
ER
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
KS1PLATFORM
GROUND
87
30
85
86
G6
G6
CB120A
33000 ufC2
ENGINESTART
CR1
BA
TT
ER
Y1
2V
DC
B1 D1
D1
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
B412V DC
(+)
()-
GROUND
M3
M3
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3GL
OW
PL
UG
U32
U32
FUELCR8
ECMPOWER TOCR43
ENGINE RUNCR25
PLUGGLOWCR15
HIGH IDLECR4
8730
85 86
8730
85 86
8730
85 86
8730
85 86
8730
85 86
2000R7
()-
(+) B112V DC
(PU
LL
)
(HO
LD
)
Q8
FU
EL
SH
UT
OF
F
Q8
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
OIL
PR
ES
SU
RE
SW
ITC
H
SW2
J4
-B2
SW2
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
SW1
J4
-B1
SW1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
F930A
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
Y10 Y10A
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
J1-C1\C4
CR17
87
30
85
86
SW4
SW4
HY
DR
AU
LIC
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
M1
N.O.
F9A20A
HY
DR
AU
LIC
OIL
CO
OL
ING
FA
N(O
PT
ION
)
M1
BN68START
J4
-A2
L30
L30WO
RK
LIG
HT
S(O
PT
ION
)
HYDRAULICOIL COOLER
(OPTION)
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 67
Electrical SchematicDiesel Models (from serial number 41200 to 41823)
Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7140P
J3
-A1
J3
-A3
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
ELECTRONIC CONTROL MODULE
U5
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
(OPTION)
J3
-A2
N.C.
LS6PLATFORM
DOWN
P1EMERGENCY
STOP
BN90GLOWPLUG
TS54HIGHIDLE
BN83PLATFORM
UP
BN84PLATFORM
DOWN
J4
-A3
J4
-A4
J2
-A1
J2
-A2
BN44 FUNCTIONENABLE
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
MODELS
WITHOUT
OUTRIGGERS
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March 2005Section 6 • Schematics
REV B
6 - 68 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 41200 to 41823)Part 3 of 3
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN23
PIN24
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
RR OUTRIGGER BN24
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITH OUTRIGGERS)
PLATFORM & OUTRIGGERUP/DOWN TS21
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 69
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March 2005Section 6 • Schematics
REV A
6 - 70 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 41824 to GS6803-42381)Part 1 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF ES7140R
EN
GIN
ES
TA
RT
ER
HO
UR
ME
TE
R
J1
-C11
,C1
2
J4
-C4
J2
-A5
ALT
ER
NA
TO
R
J4
-B4
J4
-C3
J4
-A5
J4
-B5
F
R
PLATFORM
GROUND
87
30
85
86
G6
G6
CB120A
33000 ufC2
ENGINESTART
CR1
BA
TT
ER
Y1
2V
DC
B1 D1
D1
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
(OP
TIO
N)
H2
CR5
87
30
85
86
H2
J2
-B11
GROUND
M3
M3
Q3
HIG
HID
LE
SO
LE
NO
ID
Q3GL
OW
PL
UG
U32
U32
FUELCR8
ECMPOWER TOCR43
ENGINE RUNCR25
PLUGGLOWCR15
HIGH IDLECR4
87 30
85 86
87 30
85 86
87 30
85 86
87 30
85 86
87 30
85 86
2000R7
()-
(+) B112V DC
(PU
LL
)
(HO
LD
)
Q8
FU
EL
SH
UT
OF
F
Q8
FL
AS
HIN
GB
EA
CO
N(O
PT
ION
)
FB1
J1
-B1
FB1
OIL
PR
ES
SU
RE
SW
ITC
H
SW2
J4
-B2
SW2
CO
OL
AN
TT
EM
PE
RA
TU
RE
SW
ITC
H
SW1
J4
-B1
SW1
TILT
AL
AR
M
H1
H1
J2
-B1
2
TE
MP
ER
AT
UR
EL
ED
CO
OL
AN
T
L41
J2
-B7
OIL
PR
ES
SU
RE
LE
D
L42
J2
-B8
L41
L42
N.C.N.O.
GE
NE
RA
TO
R(O
PT
ION
)
Y29GE
NE
RA
TO
RO
NL
ED
L27
J4
-B6
L27
ELECTRONIC CONTROL MODULE
U5
F930A
(GS
-32
68
ON
LY)
PL
AT
FO
RM
DO
WN
Y7A
PL
AT
FO
RM
DO
WN
Y7
J1
-A9
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
Y10 Y10A
DO
WN
(GS
-32
68
ON
LY)
AU
XIL
IAR
YP
LA
TF
OR
M
J1-C1\C4
CR17
87
30
85
86
SW4
SW4
HY
DR
AU
LIC
OIL
TE
MP
ER
AT
UR
ES
WIT
CH
M1
N.O.
F9A20A
HY
DR
AU
LIC
OIL
CO
OL
ING
FA
N(O
PT
ION
)
M1
BN68START
J4
-A2
L30
L30WO
RK
LIG
HT
S(O
PT
ION
)
HYDRAULICOIL COOLER
(OPTION)
B
KS1KEY SWITCH
B1
2
4
3
87a
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 71
Electrical SchematicDiesel Models (from serial number 41824 to GS6803-42381)
Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7140R
J3
-A1
J3
-A3
DR
IVE
PA
RA
LL
EL
Y1
J1
-A1
0
J1
-A11
J1
-A1
2
J1
-B3
ST
EE
RR
IGH
T
Y3
J1
-A1
BR
AK
ER
EL
EA
SE
Y2
J1
-A4
DR
IVE
FO
RW
AR
D
Y6
J1
-A5
DR
IVE
RE
VE
RS
E
Y5
J1
-A6
DR
IVE
FO
RW
AR
D
Y6A
J1
-A7
DR
IVE
RE
VE
RS
E
Y5A
J1
-A8
PL
AT
FO
RM
UP
Y8
J1
-A3
ST
EE
RL
EF
T
Y4
J1
-A2
DR
IVE
PA
RA
LL
EL
DR
IVE
PA
RA
LL
EL
Y1A Y1B
FL
OW
CO
NT
RO
LP
RO
PO
RT
ION
AL
Y9
ELECTRONIC CONTROL MODULE
U5
DA
TA
LIN
K(+
)B
K
GR
OU
ND
FR
OM
PL
AT
FO
RM
J3
-B4
J3
-A4
DA
TA
LIN
K(-)
YL
J3
-A5
A
CC
A
B B
D D
E E
QD4
J2
-C1
/C1
0
G8
DISPLAYDIAGNOSTIC
J2
-A8
J3
-A6
J2
-A1
0
J3
-B5
N.O. N.O.N.O. N.O.
LS12LEFT
FRONTOUTRIGGER
LS14LEFT
REAROUTRIGGER
LS13RIGHT
FRONTOUTRIGGER
LS15RIGHTREAR
OUTRIGGER
LE
FT
FR
ON
TO
UT
RIG
GE
R
LE
FT
RE
AR
OU
TR
IGG
ER
RIG
HT
RE
AR
OU
TR
IGG
ER
OU
TR
IGG
ER
EX
TE
ND
OU
TR
IGG
ER
RE
TR
AC
T
OU
TR
IGG
ER
EX
TE
ND
SL
OW
BK
S9Y35 Y44Y39Y40Y34Y33
RIG
HT
FR
ON
TO
UT
RIG
GE
R
Y36
J3
-B1
J3
-B2
J1
-B2
J1
-B6
J1
-B7
J1
-B8
J2
-B1
0
J2
-B1
J2
-B3
RD
BL
YL
J1
-B5
S82-AXISLEVEL
SENSOR
SE
NS
OR
AU
TO
LE
VE
LIN
G
OUTRIGGERS(OPTION)
PS3PLATFORMOVERLOAD
J2
-A7
N.O.
(OPTION)
J3
-A2
N.C.
LS6PLATFORM
DOWN
P1EMERGENCY
STOP
BN90GLOWPLUG
TS54HIGHIDLE
BN83PLATFORM
UP
BN84PLATFORM
DOWN
J4
-A3
J4
-A4
J2
-A1
J2
-A2
BN44 FUNCTIONENABLE
J1
-C7
,C8
J2
-A6
J2
-B1
0
RD WH
BN
N.C.
S7LEVEL
SENSOR
LEVELSENSORCIRCUITBOARD
MODELS
WITHOUT
OUTRIGGERS
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March 2005Section 6 • Schematics
REV A
6 - 72 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicDiesel Models (from serial number 41824 to GS6803-42381)Part 3 of 3
ENGINE START BN2
HIGH IDLE BN4
ENGINE STOP BN1PIN5
PIN6
PIN10
HORN BN5PIN19
POWER LED L19
POUT5
POUT3
POUT4
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
GENERATOR BN7
HIGH TORQUE BN6PIN23
PIN24
PLATFORM EXT/RET ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
PLATFORM UP/DOWN TS20
LIFT ENABLE LOW BN13
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITHOUT OUTRIGGERS)
STARTING AID BN3PIN29
ENGINE START BN2
AUTO LEVEL BN20
ENGINE STOP BN1PIN5
PIN6
PIN10
HIGH TORQUE/LF OUTRIGGER BN17PIN19
POWER LED L19
POUT5
POUT3
POUT4
LIFT ERROR INDICATOR LED L57
POUT6
POUT8
FAULT LED L25
POUT2
GENERATOR LED L27
HIGH TORQUE LED L21
HIGH IDLE LED L23
PLATFORM CONTROLSMEMBRANE DECAL
H1ALARM
POUT1
PIN11
RD +
-BK
BK
P2EMERGENCY
STOPBK
RD
SW25DIPSWITCH
PIO3
PIO5
PIO4
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
A RD
C
WHB
BLD
YLE
QD3
D7VOLTAGE
REGULATOR
5V DC
12V DC
PIO2
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
1
2
3
4
5
6
7
8
A
C
B
D
E
RR OUTRIGGER BN24
HORN/LR OUTRIGGER BN15
HIGH IDLE BN4PIN23
PIN24
PIN13
OUTRIGGER ENABLE BN16PIN25
PIN1
PIN2
PIN3
PIN4
WH
BL
RD
YL
UP
DOWN
LIFT ENABLE HIGH BN12
LIFT ENABLE LOW BN13
GENERATOR/RF OUTRIGGER BN18PIN25
BN
OR
PIN15
PIN14
PIN18WH/BL
WH/RD
WH
JC1JOYSTICK
CONTROLLER
WH/BK
SW6
LE
FT
RIG
HT
SW5FUNCTION ENABLE
WH/YL
PP
R155KPOTENTIOMETER
STEERLEFT/ RIGHT
PLATFORM CONTROLS(DIESEL MODELS WITH OUTRIGGERS)
PLATFORM & OUTRIGGERUP/DOWN TS21
STARTING AID BN3PIN29
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 73
This page intentionally left blank.
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March 2005Section 6 • Schematics
REV A
6 - 74 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicANSI Models with Diesel Power(from serial number GS6803-42382 to GS6805-43594)Part 1 of 3
PLATFORMCONTROL
GROUNDCONTROL
CB2 20A
B1
12
VO
LTB
AT
TE
RY
J1
-C2
J2
-B8
J2
-B7
CR41CONTROLSYSTEM
P1EMERGENCY STOP
CR5HORN
CR42POWER
CR8IGNITION
CR1ENGINESTART
KS1 KEY SWITCH
J2
-B11
M3
STA
RT
ER
MO
TO
R
K1
STA
RT
ER
RE
LA
Y
-
+
B1
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
Q8
FU
EL
SH
UT
OF
F
Q8FUELSHUTOFF
STARTER
M3
H2
H2
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
D1EXCT
D1
ALT
ER
NA
TO
R
U3
2G
LO
WP
LU
G(O
PT
ION
)
CR15STARTINGAID
U32GLOWPLUG
(OPTION)
B
B1
4
2
3
CR23AUXILIARYDOWN
J2
-A4
J2-C4
J2-B9
J1-C7
J2
-C1
/C3
J2
-A3
BN23AUXILIARY DOWN
BN91AUXILIARY DOWNENABLE
J2
-A5
LS6PLAT
DOWNLIMIT
SWITCH
J2
-A2
N.C.
(PU
LL
)
(HO
LD
)
30AF9
KU
BO
TA
DIE
SE
LO
NLY
BAT
STA
G6
EN
GIN
EH
OU
RM
ET
ER
G6HOUR
METER
Y8
PL
AT
FO
RM
UP
Y8
Y7
PL
AT
FO
RM
DO
WN
J1
-A3
Y7
Y1
0A
UX
PL
AT
FO
RM
DO
WN
Y7
AP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y1
0A
AU
XP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y10
Y7A Y10A
U5ECM
ES7162A
J1
-A9
J2
-C1
2
AB3
AB1
AB1
AB3AB3AB7
Q3
HIG
HID
LE
SO
LE
NO
ID
CR4HIGH IDLE
Q3HIGH IDLESOLENOID
L30WORKLIGHTS
L3
0W
OR
KL
IGH
TS
(OP
TIO
N)
C54700 uF
AB28
85
86 30
87 87A
6
85
86 30
87 87A
4
85
86 30
87 87A
2
85
86 30
87 87A
1
85
86 30
87 87A
8
85
86 30
87 87A
7
85
86 30
87 87A
5
85
86 30
87 87A
3
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 75
Electrical SchematicANSI Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
SW
1C
OO
LA
NT
TE
MP
ER
AT
UR
ES
WIT
CH
SW1
J1
-C9
SW
2O
ILP
RE
SS
UR
ES
WIT
CH
SW2
J1
-C8
U5ELECTRONIC CONTROL MODULE
FB
1F
LA
SH
ING
BE
AC
ON
(OP
TIO
N)
J2
-C11
FB1H5
H5
AL
AR
MJ2
-B1
2
Y2
9G
EN
ER
AT
OR
(OP
TIO
N)
J1
-B1
S7
LE
VE
LS
EN
SO
R
EC
MG
RO
UN
DJ2
-C7
Y2
J1
-A4
Y4
ST
EE
RL
EF
T
Y1
DR
IVE
PA
RA
LL
EL
Y2
BR
AK
ER
EL
EA
SE
Y3
ST
EE
RR
IGH
T
J1
-A2
Y3
Y4
J1
-A1
0
J1
-A11
Y1
J1
-A1
2
Y1B
J1
-A1
Y1A
J1
-A5
Y5
Y6
J1
-A7
J1
-A8
Y6A
J1
-B3
Y9
J1
-A6
Y5A
Y1
AD
RIV
EP
AR
AL
LE
L
Y1
BD
RIV
EP
AR
AL
LE
L
Y6
DR
IVE
FO
RW
AR
D(1
)
Y6
AD
RIV
EF
OR
WA
RD
(2)
Y5
DR
IVE
RE
VE
RS
E(1
)
Y5
AD
RIV
ER
EV
ER
SE
(2)
Y9
PR
OP
OR
TIO
NA
LF
LO
WC
ON
TR
OL
Y29
ES7162A
BK
RD
WH
N.C.LEVEL SENSORCIRCUIT BOARD
MODELS WITHOUT
OUTRIGGERS
S7 LEVELSENSOR
J2
-B2
J2
-A6
J2
-B1
0
AB29
AB1
AB23
CR17
SW4
M1
N.O.F9A20A
85
8630
87
HYDRAULICOIL COOLER(OPTION)
BATTERY (-)
BATTERY (+)
CR8 TERMINAL 30 AB2
AB13AB11AB22
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March 2005Section 6 • Schematics
REV A
6 - 76 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicANSI Models with Diesel Power(from serial number GS6803-42382 to GS6805-43594)Part 3 of 3
J1
-C3
J1
-C4
J1
-C6
LS14LR
O-RIGLIMIT
SWITCH
LS15RR
O-RIGLIMIT
SWITCH
LS13RF
O-RIGLIMIT
SWITCH
J1
-C5
N.O. N.O. N.O. N.O.
LS12LF
O-RIGLIMIT
SWITCH
OUTRIGGERS(OPTION)
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
U5ELECTRONIC
CONTROLMODULE
GN
DF
RO
MP
LA
TJ2
-A1
0
WH/RD
RD/WH
1BL
2BK
5OR
QD4
3
4
DA
TA
LIN
K(-)
DA
TA
LIN
K(+
)J2
-A11
J2
-A1
2
1
2
5
3
4
PLATFORM
CONTROLS
BK
RD
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
3 RD
4
WH1
BL2
OR5
QD3
D7VOLTAGE
REGULATOR5V DC
12V DC
J5 PIN2
3
4
1
2
5
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
J5 PIN5
J5 PIN4
J5 PIN1WH
BL
OR
JC1JOYSTICK
CONTROLLER
SW6STEERLEFT/ RIGHT
LE
FT
RIG
HT
SW5FUNCTION ENABLE
J2 PIN6
J2 PIN7
J2 PIN4
J2 PIN5
BK
RD
OR
PP
WH
BN
HALL EFFECTGENERATOR
GYJ2 PIN1
J2 PIN12
J2 PIN13
YLJ2 PIN2
J2 PIN3BL
WH/BLJ2 PIN8
H1ALARM
J3 PIN2
J3 PIN1RD +
BK
POUT1
PIN14
HORN BN5
ENGINE START BN2
PIN2
PIN3
PIN4
STARTING AID BN3
ORGR AUTOLEVEL ENABLE BN20
PIN7 LPG SELECT BN14
PIN6 GENERATOR BN7
PIN9 LF OUTRIGGER ENABLE BN85
PIN8 HIGH IDLE BN4
PIN11 LR OUTRIGGER ENABLE BN87
PIN10 RF OUTRIGGER ENABLE BN86
PIN13 LIFT FUNCTION BN9
PIN12 RR OUTRIGGER ENABLE BN24
PIN5 HIGH TORQUE BN6
PIN15 SYSTEM STATUS L50
GYJ5 PIN3
J2 PIN14
BL
RD
BK
YLJ1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
PLATFORM UP/DOWN TS20-OR-
PLATFORM & OUTRIGGERUP/DOWN
TS21
EMERGENCYSTOP
P2
ES7162A
Y36 Y34
Y35 Y33
J1
-B11
J1
-B9
J1
-B5
Y3
4R
IGH
TR
EA
RO
UT
RIG
GE
R
Y3
5L
EF
TF
RO
NT
OU
TR
IGG
ER
Y3
6R
IGH
TF
RO
NT
OU
TR
IGG
ER
J1
-B1
0Y
33
LE
FT
RE
AR
OU
TR
IGG
ER
Y4
0O
UT
RIG
GE
RE
XT
EN
D
Y3
9O
UT
RIG
GE
RR
ET
RA
CT
S8
2-A
XIS
LE
VE
LS
EN
SO
R
Y40 Y44
J1
-B8
J1
-B6
Y39
J1
-B7
Y4
4O
UT
RIG
GE
RD
OW
NS
LO
W
AB3 AB3 AB2 AB2
AB16AB17AB26AB27
AB9 AB15 AB8 AB6
AB10 AB14 AB7
S82 AXIS
TILT LEVELSENSOR
J2
-B1
0R
DP
OW
ER
J2
-B3
YL
RO
LL
J2
-B1
BL
PIT
CH
J2
-B2
BK
GR
OU
ND
AB1AB25
AB24AB23
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 77
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March 2005Section 6 • Schematics
REV A
6 - 78 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicANSI Models with Diesel Power(after serial number GS6805-43594)Part 1 of 3
ES7162D
CB2 20A
B1
12
VO
LTB
AT
TE
RY
J1
-C2
J2
-B8
J2
-B7
CR41CONTROLSYSTEM
CR5HORN
CR42POWER
CR8IGNITION
CR1ENGINESTART
J2
-B11
M3
STA
RT
ER
MO
TO
R
K1
STA
RT
ER
RE
LA
Y
-
+
B1
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
Q8
FU
EL
SH
UT
OF
F
Q8FUELSHUTOFF
STARTER
M3
H2
H2
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
D1EXCT
D1
ALT
ER
NA
TO
R
U3
2G
LO
WP
LU
G(O
PT
ION
)
CR15STARTINGAID
U32GLOWPLUG
(OPTION)
CR23AUXILIARYDOWN
J2
-A4
J2-C4
J2-B9
J1-C7
J2
-C1
/C3
J2
-A3
BN23AUXILIARY DOWN
BN91AUXILIARY DOWNENABLE
J2
-A5
LS6PLAT
DOWNLIMIT
SWITCH
J2
-A2
N.C.
(PU
LL
)
(HO
LD
)
30AF9
KU
BO
TA
DIE
SE
LO
NLY
BAT
STA
G6
EN
GIN
EH
OU
RM
ET
ER
G6HOUR
METER
Y8
PL
AT
FO
RM
UP
Y8
Y7
PL
AT
FO
RM
DO
WN
J1
-A3
Y7
Y1
0A
UX
PL
AT
FO
RM
DO
WN
Y7
AP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y1
0A
AU
XP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y10
Y7A Y10A
U5ECM
J1
-A9
J2
-C1
2
AB3
AB1
AB1
AB3AB3AB7
Q3
HIG
HID
LE
SO
LE
NO
ID
CR4HIGH IDLE
Q3HIGH IDLESOLENOID
L30WORKLIGHTS
L3
0W
OR
KL
IGH
TS
(OP
TIO
N)
C54700 uF
AB28
P1EMERGENCY STOPF9 5A FUSE
PLATFORMCONTROL
GROUNDCONTROL
B
B1
4
2
3
KS1 KEY SWITCH
85
86 30
87 87A
6
85
86 30
87 87A
4
85
86 30
87 87A
2
85
86 30
87 87A
1
85
86 30
87 87A
8
85
86 30
87 87A
7
85
86 30
87 87A
5
85
86 30
87 87A
3
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 79
Electrical SchematicANSI Models with Diesel Power
(after serial number GS6805-43594)Part 2 of 3
ES7162D
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
SW
1C
OO
LA
NT
TE
MP
ER
AT
UR
ES
WIT
CH
SW1
J1
-C9
SW
2O
ILP
RE
SS
UR
ES
WIT
CH
SW2
J1
-C8
U5ELECTRONIC CONTROL MODULE
FB
1F
LA
SH
ING
BE
AC
ON
(OP
TIO
N)
J2
-C11
FB1H5
H5
AL
AR
MJ2
-B1
2
Y2
9G
EN
ER
AT
OR
(OP
TIO
N)
J1
-B1
S7
LE
VE
LS
EN
SO
R
EC
MG
RO
UN
DJ2
-C7
Y2
J1
-A4
Y4
ST
EE
RL
EF
T
Y1
DR
IVE
PA
RA
LL
EL
Y2
BR
AK
ER
EL
EA
SE
Y3
ST
EE
RR
IGH
T
J1
-A2
Y3
Y4
J1
-A1
0
J1
-A11
Y1
J1
-A1
2
Y1B
J1
-A1
Y1A
J1
-A5
Y5
Y6
J1
-A7
J1
-A8
Y6A
J1
-B3
Y9
J1
-A6
Y5A
Y1
AD
RIV
EP
AR
AL
LE
L
Y1
BD
RIV
EP
AR
AL
LE
L
Y6
DR
IVE
FO
RW
AR
D(1
)
Y6
AD
RIV
EF
OR
WA
RD
(2)
Y5
DR
IVE
RE
VE
RS
E(1
)
Y5
AD
RIV
ER
EV
ER
SE
(2)
Y9
PR
OP
OR
TIO
NA
LF
LO
WC
ON
TR
OL
Y29
BK
RD
WH
N.C.LEVEL SENSORCIRCUIT BOARD
MODELS WITHOUT
OUTRIGGERS
S7 LEVELSENSOR
J2
-B2
J2
-A6
J2
-B1
0
AB29
AB1
AB23
CR17
SW4
M1
N.O.F9A20A
85
8630
87
HYDRAULICOIL COOLER(OPTION)
BATTERY (-)
BATTERY (+)
CR8 TERMINAL 30 AB2
AB13AB11AB22
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March 2005Section 6 • Schematics
REV A
6 - 80 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicANSI Models with Diesel Power(after serial number GS6805-43594)Part 3 of 3
J1
-C3
J1
-C4
J1
-C6
LS14LR
O-RIGLIMIT
SWITCH
LS15RR
O-RIGLIMIT
SWITCH
LS13RF
O-RIGLIMIT
SWITCH
J1
-C5
N.O. N.O. N.O. N.O.
LS12LF
O-RIGLIMIT
SWITCH
OUTRIGGERS(OPTION)
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
U5ELECTRONIC
CONTROLMODULE
GN
DF
RO
MP
LA
TJ2
-A1
0
WH/RD
RD/WH
1BL
2BK
5OR
QD4
3
4
DA
TA
LIN
K(-)
DA
TA
LIN
K(+
)J2
-A11
J2
-A1
2
1
2
5
3
4
PLATFORM
CONTROLS
BK
RD
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
3 RD
4
WH1
BL2
OR5
QD3
D7VOLTAGE
REGULATOR5V DC
12V DC
J5 PIN2
3
4
1
2
5
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
J5 PIN5
J5 PIN4
J5 PIN1WH
BL
OR
JC1JOYSTICK
CONTROLLER
SW6STEERLEFT/ RIGHT
LE
FT
RIG
HT
SW5FUNCTION ENABLE
J2 PIN6
J2 PIN7
J2 PIN4
J2 PIN5
BK
RD
OR
PP
WH
BN
HALL EFFECTGENERATOR
GYJ2 PIN1
J2 PIN12
J2 PIN13
YLJ2 PIN2
J2 PIN3BL
WH/BLJ2 PIN8
H1ALARM
J3 PIN2
J3 PIN1RD +
BK
POUT1
PIN14
HORN BN5
ENGINE START BN2
PIN2
PIN3
PIN4
STARTING AID BN3
ORGR AUTOLEVEL ENABLE BN20
PIN7 LPG SELECT BN14
PIN6 GENERATOR BN7
PIN9 LF OUTRIGGER ENABLE BN85
PIN8 HIGH IDLE BN4
PIN11 LR OUTRIGGER ENABLE BN87
PIN10 RF OUTRIGGER ENABLE BN86
PIN13 LIFT FUNCTION BN9
PIN12 RR OUTRIGGER ENABLE BN24
PIN5 HIGH TORQUE BN6
PIN15 SYSTEM STATUS L50
GYJ5 PIN3
J2 PIN14
BL
RD
BK
YLJ1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
PLATFORM UP/DOWN TS20-OR-
PLATFORM & OUTRIGGERUP/DOWN
TS21
EMERGENCYSTOP
P2
ES7162D
Y36 Y34
Y35 Y33
J1
-B11
J1
-B9
J1
-B5
Y3
4R
IGH
TR
EA
RO
UT
RIG
GE
R
Y3
5L
EF
TF
RO
NT
OU
TR
IGG
ER
Y3
6R
IGH
TF
RO
NT
OU
TR
IGG
ER
J1
-B1
0Y
33
LE
FT
RE
AR
OU
TR
IGG
ER
Y4
0O
UT
RIG
GE
RE
XT
EN
D
Y3
9O
UT
RIG
GE
RR
ET
RA
CT
S8
2-A
XIS
LE
VE
LS
EN
SO
R
Y40 Y44
J1
-B8
J1
-B6
Y39
J1
-B7
Y4
4O
UT
RIG
GE
RD
OW
NS
LO
W
AB3 AB3 AB2 AB2
AB16AB17AB26AB27
AB9 AB15 AB8 AB6
AB10 AB14 AB7
S82 AXIS
TILT LEVELSENSOR
J2
-B1
0R
DP
OW
ER
J2
-B3
YL
RO
LL
J2
-B1
BL
PIT
CH
J2
-B2
BK
GR
OU
ND
AB1AB25
AB24AB23
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 81
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March 2005Section 6 • Schematics
REV A
6 - 82 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicCE Models with Diesel Power(from serial number GS6803-42382 to GS6805-43594)Part 1 of 3
PLATFORMCONTROL
GROUNDCONTROL
CB2 20A
B1
12
VO
LTB
AT
TE
RY
J1
-C2
J2
-B8
J2
-B7
CR41CONTROLSYSTEM
P1EMERGENCY STOP
CR5HORN
CR42POWER
CR8IGNITION
CR1ENGINESTART
KS1 KEY SWITCH
J2
-B11
M3
STA
RT
ER
MO
TO
R
K1
STA
RT
ER
RE
LA
Y
-
+
B1
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
Q8
FU
EL
SH
UT
OF
F
Q8FUELSHUTOFF
STARTER
M3
H2
H2
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
D1EXCT
D1
ALT
ER
NA
TO
R
U3
2G
LO
WP
LU
G(O
PT
ION
)
CR15STARTINGAID
U32GLOWPLUG
(OPTION)
ES7162A
B
B1
4
2
3
CR23AUXILIARYDOWN
J2
-A4
J2-C4
J2-B9
J1-C7
J2
-C1
/C3
PS2PLATFORMOVERLOADPRESSURE
SWITCH
J2
-A3
BN23AUXILIARY DOWN
BN91AUXILIARY DOWNENABLE
J2
-A5
Q3
HIG
HID
LE
SO
LE
NO
ID
CR4HIGH IDLE
Q3HIGH IDLESOLENOID
C54700 uF
LS6PLAT
DOWNLIMIT
SWITCH
J2
-A2
N.C.
L30WORKLIGHTS
L3
0W
OR
KL
IGH
TS
(OP
TIO
N)
(PU
LL
)
(HO
LD
)
30AF9
KU
BO
TA
DIE
SE
LO
NLY
BAT
STA
G6
EN
GIN
EH
OU
RM
ET
ER
G6HOUR
METER
Y8
PL
AT
FO
RM
UP
Y8
Y7
PL
AT
FO
RM
DO
WN
LS25LOAD SENSEDELAYLIMIT SW
N.C.
J1
-A9
CR77DOWN
ENABLE
87A85
86 30
87
9
LS24MAXIMUMHEIGHTLIMIT SW
N.C.
J1
-A3
Y7
Y1
0A
UX
PL
AT
FO
RM
DO
WN
Y7
AP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y1
0A
AU
XP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y10
Y7A Y10A
U5ECM
J2
-C1
2
AB3AB7
AB1
AB1
AB4
AB20
AB12
AB28
AB3
85
86 30
87 87A
6
85
86 30
87 87A
4
85
86 30
87 87A
2
85
86 30
87 87A
1
85
86 30
87 87A
8
85
86 30
87 87A
7
85
86 30
87 87A
5
85
86 30
87 87A
3
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 83
Electrical SchematicCE Models with Diesel Power
(from serial number GS6803-42382 to GS6805-43594)Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7162A
SW
1C
OO
LA
NT
TE
MP
ER
AT
UR
ES
WIT
CH
SW1
J1
-C9
SW
2O
ILP
RE
SS
UR
ES
WIT
CH
SW2
J1
-C8
U5ELECTRONIC CONTROL MODULE
FB
1F
LA
SH
ING
BE
AC
ON
(OP
TIO
N)
J2
-C11
FB1H5
H5
AL
AR
MJ2
-B1
2
Y2
9G
EN
ER
AT
OR
(OP
TIO
N)
J1
-B1
S7
LE
VE
LS
EN
SO
R
EC
MG
RO
UN
DJ2
-C7
Y2
J1
-A4
Y4
ST
EE
RL
EF
T
Y1
DR
IVE
PA
RA
LL
EL
Y2
BR
AK
ER
EL
EA
SE
Y3
ST
EE
RR
IGH
T
J1
-A2
Y3
Y4
J1
-A1
0
J1
-A11
Y1
J1
-A1
2
Y1B
J1
-A1
Y1A
CR17
SW4
M1
N.O.F9A20A
85
8630
87
HYDRAULICOIL COOLER(OPTION)
BATTERY (-)
BATTERY (+)
CR8 TERMINAL 30
J1
-A5
Y5
Y6
J1
-A7
J1
-A8
Y6A
J1
-B3
Y9
J1
-A6
Y5A
Y1
AD
RIV
EP
AR
AL
LE
L
Y1
BD
RIV
EP
AR
AL
LE
L
Y6
DR
IVE
FO
RW
AR
D(1
)
Y6
AD
RIV
EF
OR
WA
RD
(2)
Y5
DR
IVE
RE
VE
RS
E(1
)
Y5
AD
RIV
ER
EV
ER
SE
(2)
Y9
PR
OP
OR
TIO
NA
LF
LO
WC
ON
TR
OL
Y29
BK
RD
WH
N.C.LEVEL SENSORCIRCUIT BOARD
MODELS WITHOUT
OUTRIGGERS
S7 LEVELSENSOR
J2
-B2
J2
-A6
J2
-B1
0
AB11
AB2
AB13
AB29
AB1
AB23
AB22
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March 2005Section 6 • Schematics
REV A
6 - 84 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicCE Models with Diesel Power(from serial number GS6803-42382 to GS6805-43594)Part 3 of 3
J1
-C3
J1
-C4
J1
-C6
LS14LR
O-RIGLIMIT
SWITCH
LS15RR
O-RIGLIMIT
SWITCH
LS13RF
O-RIGLIMIT
SWITCH
J1
-C5
N.O. N.O. N.O. N.O.
LS12LF
O-RIGLIMIT
SWITCH
OUTRIGGERS(OPTION)
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
U5ELECTRONIC
CONTROLMODULE
GN
DF
RO
MP
LA
TJ2
-A1
0
WH/RD
RD/WH
1BL
2BK
5OR
QD4
3
4
DA
TA
LIN
K(-)
DA
TA
LIN
K(+
)J2
-A11
J2
-A1
2
1
2
5
3
4
PLATFORM
CONTROLS
BK
RD
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
3 RD
4
WH1
BL2
OR5
QD3
D7VOLTAGE
REGULATOR5V DC
12V DC
J5 PIN2
3
4
1
2
5
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
J5 PIN5
J5 PIN4
J5 PIN1WH
BL
OR
JC1JOYSTICK
CONTROLLER
SW6STEERLEFT/ RIGHT
LE
FT
RIG
HT
SW5FUNCTION ENABLE
J2 PIN6
J2 PIN7
J2 PIN4
J2 PIN5
BK
RD
OR
PP
WH
BN
HALL EFFECTGENERATOR
GYJ2 PIN1
J2 PIN12
J2 PIN13
YLJ2 PIN2
J2 PIN3BL
WH/BLJ2 PIN8
H1ALARM
J3 PIN2
J3 PIN1RD +
BK
POUT1
PIN14
HORN BN5
ENGINE START BN2
PIN2
PIN3
PIN4
STARTING AID BN3
ORGR AUTOLEVEL ENABLE BN20
PIN7 LPG SELECT BN14
PIN6 GENERATOR BN7
PIN9 LF OUTRIGGER ENABLE BN85
PIN8 HIGH IDLE BN4
PIN11 LR OUTRIGGER ENABLE BN87
PIN10 RF OUTRIGGER ENABLE BN86
PIN13 LIFT FUNCTION BN9
PIN12 RR OUTRIGGER ENABLE BN24
PIN5 HIGH TORQUE BN6
PIN15 SYSTEM STATUS L50
GYJ5 PIN3
J2 PIN14
BL
RD
BK
YLJ1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
PLATFORM UP/DOWN TS20-OR-
PLATFORM & OUTRIGGERUP/DOWN
TS21
EMERGENCYSTOP
P2
ES7162A
Y36 Y34
Y35 Y33
J1
-B11
J1
-B9
J1
-B5
Y3
4R
IGH
TR
EA
RO
UT
RIG
GE
R
Y3
5L
EF
TF
RO
NT
OU
TR
IGG
ER
Y3
6R
IGH
TF
RO
NT
OU
TR
IGG
ER
J1
-B1
0Y
33
LE
FT
RE
AR
OU
TR
IGG
ER
Y4
0O
UT
RIG
GE
RE
XT
EN
D
Y3
9O
UT
RIG
GE
RR
ET
RA
CT
S8
2-A
XIS
LE
VE
LS
EN
SO
R
Y40 Y44
J1
-B8
J1
-B6
Y39
J1
-B7
Y4
4O
UT
RIG
GE
RD
OW
NS
LO
W
AB3 AB3 AB2 AB2
AB16AB17AB26AB27
AB9 AB15 AB8 AB6
AB10 AB14 AB7
S82 AXIS
TILT LEVELSENSOR
J2
-B1
0R
DP
OW
ER
J2
-B3
YL
RO
LL
J2
-B1
BL
PIT
CH
J2
-B2
BK
GR
OU
ND
AB1AB25
AB24AB23
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 85
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March 2005Section 6 • Schematics
REV A
6 - 86 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicCE Models with Diesel Power(after serial number GS6805-43594)Part 1 of 3
CB2 20A
B1
12
VO
LTB
AT
TE
RY
J1
-C2
J2
-B8
J2
-B7
CR41CONTROLSYSTEM
CR5HORN
CR42POWER
CR8IGNITION
CR1ENGINESTART
J2
-B11
M3
STA
RT
ER
MO
TO
R
K1
STA
RT
ER
RE
LA
Y
-
+
B1
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
Q8
FU
EL
SH
UT
OF
F
Q8FUELSHUTOFF
STARTER
M3
H2
H2
AU
TO
MO
TIV
E-S
TY
LE
HO
RN
D1EXCT
D1
ALT
ER
NA
TO
R
U3
2G
LO
WP
LU
G(O
PT
ION
)
CR15STARTINGAID
U32GLOWPLUG
(OPTION)
ES7184B
CR23AUXILIARYDOWN
J2
-A4
J2-C4
J2-B9
J1-C7
J2
-C1
/C3
PS2PLATFORMOVERLOADPRESSURE
SWITCH
J2
-A3
BN23AUXILIARY DOWN
BN91AUXILIARY DOWNENABLE
J2
-A5
Q3
HIG
HID
LE
SO
LE
NO
ID
CR4HIGH IDLE
Q3HIGH IDLESOLENOID
LS6PLAT
DOWNLIMIT
SWITCH
J2
-A2
N.C.
L30WORKLIGHTS
L3
0W
OR
KL
IGH
TS
(OP
TIO
N)
(PU
LL
)
(HO
LD
)
30AF9
KU
BO
TA
DIE
SE
LO
NLY
BAT
STA
G6
EN
GIN
EH
OU
RM
ET
ER
G6HOUR
METER
Y8
PL
AT
FO
RM
UP
Y8
Y7
PL
AT
FO
RM
DO
WN
LS25LOAD SENSEDELAYLIMIT SW
N.C.
J1
-A9
CR77DOWN
ENABLE
87A85
86 30
87
9
LS24MAXIMUMHEIGHTLIMIT SW
N.C.
J1
-A3
Y7
Y1
0A
UX
PL
AT
FO
RM
DO
WN
Y7
AP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y1
0A
AU
XP
LA
TF
OR
MD
OW
N(G
S-3
26
8O
NLY
)
Y10
Y7A Y10A
U5ECM
J2
-C1
2
AB3AB7
AB1
AB1
AB4
AB20
AB12
AB28
P1EMERGENCY STOPF9 5A FUSE
PLATFORMCONTROL
GROUNDCONTROL
B
B1
4
2
3
KS1 KEY SWITCH
AB3
C54700 uF
85
86 30
87 87A
6
85
86 30
87 87A
4
85
86 30
87 87A
2
85
86 30
87 87A
1
85
86 30
87 87A
8
85
86 30
87 87A
7
85
86 30
87 87A
5
85
86 30
87 87A
3
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 87
Electrical SchematicCE Models with Diesel Power
(after serial number GS6805-43594)Part 2 of 3
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFFES7184B
SW
1C
OO
LA
NT
TE
MP
ER
AT
UR
ES
WIT
CH
SW1
J1
-C9
SW
2O
ILP
RE
SS
UR
ES
WIT
CH
SW2
J1
-C8
U5ELECTRONIC CONTROL MODULE
FB
1F
LA
SH
ING
BE
AC
ON
(OP
TIO
N)
J2
-C11
FB1H5
H5
AL
AR
MJ2
-B1
2
Y2
9G
EN
ER
AT
OR
(OP
TIO
N)
J1
-B1
S7
LE
VE
LS
EN
SO
R
EC
MG
RO
UN
DJ2
-C7
Y2
J1
-A4
Y4
ST
EE
RL
EF
T
Y1
DR
IVE
PA
RA
LL
EL
Y2
BR
AK
ER
EL
EA
SE
Y3
ST
EE
RR
IGH
T
J1
-A2
Y3
Y4
J1
-A1
0
J1
-A11
Y1
J1
-A1
2
Y1B
J1
-A1
Y1A
CR17
SW4
M1
N.O.F9A20A
85
8630
87
HYDRAULICOIL COOLER(OPTION)
BATTERY (-)
BATTERY (+)
CR8 TERMINAL 30
J1
-A5
Y5
Y6
J1
-A7
J1
-A8
Y6A
J1
-B3
Y9
J1
-A6
Y5A
Y1
AD
RIV
EP
AR
AL
LE
L
Y1
BD
RIV
EP
AR
AL
LE
L
Y6
DR
IVE
FO
RW
AR
D(1
)
Y6
AD
RIV
EF
OR
WA
RD
(2)
Y5
DR
IVE
RE
VE
RS
E(1
)
Y5
AD
RIV
ER
EV
ER
SE
(2)
Y9
PR
OP
OR
TIO
NA
LF
LO
WC
ON
TR
OL
Y29
BK
RD
WH
N.C.LEVEL SENSORCIRCUIT BOARD
MODELS WITHOUT
OUTRIGGERS
S7 LEVELSENSOR
J2
-B2
J2
-A6
J2
-B1
0
AB11
AB2
AB13
AB29
AB1
AB23
AB22
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March 2005Section 6 • Schematics
REV A
6 - 88 GS-2668 RT • GS-3268 RT Part No. 52302
Electrical SchematicCE Models with Diesel Power(after serial number GS6805-43594)Part 3 of 3
J1
-C3
J1
-C4
J1
-C6
LS14LR
O-RIGLIMIT
SWITCH
LS15RR
O-RIGLIMIT
SWITCH
LS13RF
O-RIGLIMIT
SWITCH
J1
-C5
N.O. N.O. N.O. N.O.
LS12LF
O-RIGLIMIT
SWITCH
OUTRIGGERS(OPTION)
- NOTE -MACHINE SHOWN IN THE STOWEDPOSITION WITH THE POWER OFF
U5ELECTRONIC
CONTROLMODULE
GN
DF
RO
MP
LA
TJ2
-A1
0
WH/RD
RD/WH
1BL
2BK
5OR
QD4
3
4
DA
TA
LIN
K(-)
DA
TA
LIN
K(+
)J2
-A11
J2
-A1
2
1
2
5
3
4
S82 AXIS
TILT LEVELSENSOR
J2
-B1
0R
DP
OW
ER
J2
-B3
YL
RO
LL
J2
-B1
BL
PIT
CH
PLATFORM
CONTROLS
BK
RD
DATA LINK (LOW)
DATA LINK (HIGH)
GROUND
POWER TO GROUND
POWER TO PLATFORMBK
3 RD
4
WH1
BL2
OR5
QD3
D7VOLTAGE
REGULATOR5V DC
12V DC
J5 PIN2
3
4
1
2
5
U3PLATFORM CONTROLS
PRINTED CIRCUIT BOARD
J5 PIN5
J5 PIN4
J5 PIN1WH
BL
OR
JC1JOYSTICK
CONTROLLER
SW6STEERLEFT/ RIGHT
LE
FT
RIG
HT
SW5FUNCTION ENABLE
J2 PIN6
J2 PIN7
J2 PIN4
J2 PIN5
BK
RD
OR
PP
WH
BN
HALL EFFECTGENERATOR
GYJ2 PIN1
J2 PIN12
J2 PIN13
YLJ2 PIN2
J2 PIN3BL
WH/BLJ2 PIN8
H1ALARM
J3 PIN2
J3 PIN1RD +
BK
POUT1
PIN14
HORN BN5
ENGINE START BN2
PIN2
PIN3
PIN4
STARTING AID BN3
ORGR AUTOLEVEL ENABLE BN20
PIN7 LPG SELECT BN14
PIN6 GENERATOR BN7
PIN9 LF OUTRIGGER ENABLE BN85
PIN8 HIGH IDLE BN4
PIN11 LR OUTRIGGER ENABLE BN87
PIN10 RF OUTRIGGER ENABLE BN86
PIN13 LIFT FUNCTION BN9
PIN12 RR OUTRIGGER ENABLE BN24
PIN5 HIGH TORQUE BN6
PIN15 SYSTEM STATUS L50
GYJ5 PIN3
J2 PIN14
BL
RD
BK
YLJ1 PIN4
J1 PIN3
J1 PIN1
J1 PIN5
PLATFORM UP/DOWN TS20-OR-
PLATFORM & OUTRIGGERUP/DOWN
TS21
EMERGENCYSTOP
P2
ES7184B
Y36 Y34
Y35 Y33
J1
-B11
J1
-B9
J1
-B5
Y3
4R
IGH
TR
EA
RO
UT
RIG
GE
R
Y3
5L
EF
TF
RO
NT
OU
TR
IGG
ER
Y3
6R
IGH
TF
RO
NT
OU
TR
IGG
ER
J1
-B1
0Y
33
LE
FT
RE
AR
OU
TR
IGG
ER
Y4
0O
UT
RIG
GE
RE
XT
EN
D
Y3
9O
UT
RIG
GE
RR
ET
RA
CT
S8
2-A
XIS
LE
VE
LS
EN
SO
R
Y40 Y44
J1
-B8
J1
-B6
Y39
J1
-B7
Y4
4O
UT
RIG
GE
RD
OW
NS
LO
W
AB3 AB3 AB2 AB2
AB16AB17AB26AB27
AB9 AB15 AB8 AB6
AB10 AB14 AB7
J2
-B2
BK
GR
OU
ND
AB1AB_
AB_AB23
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March 2005 Section 6 • Schematics
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 89
This page intentionally left blank.
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March 2005Section 6 • Schematics
REV A
6 - 90 GS-2668 RT • GS-3268 RT Part No. 52302
Hydraulic Schematics Component Call-out Legend
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
C Check valve – drive speed select circuit
D Check valve – prevents engine from running backward when on an incline and reversing direction of travel
E Check valve – steer circuit F Check valve – proportional circuit G Relief valve – pump 1 H Check valve – proportional circuit I Test port 1 J Test port 2 K Relief valve – lift circuit L Check valve - drive circuit M Shuttle valve – brake release circuit N Check valve - drive circuit O Relief valve – pump 2 P Platform up/down Q Priority flow regulator R Steer left/right S Orifice – brake release circuit T Proportional valve – lift/drive circuit U Brake release V Relief valve – steer circuit W Drive speed select circuit X Drive speed select circuit Y Drive speed select circuit Z 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 AI 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 Counterbalance valve – outrigger CA Right front outrigger autolevel valve CB Left front outrigger autolevel valve CC Right rear outrigger autolevel valve CD Left rear outrigger autolevel valve
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 91
Hydraulic Symbols Legend
0.063 in1.6 mm
E
Y44 Y1
Filter
Check valve
Engine
Fixed displacementpump
Dual acting cylinder
Single acting cylinder
Solenoid operated2 position 2 way valve,
normally closed
Counterbalancevalve
Solenoid operated2 position 2 waydirectional valve
Relief valve
Solenoid operated3 position 4 waydirectional valve
Single directionvariable speed motor
Priority flow regulator
Solenoid operated2 position 3 waydirectional valve
Platform overloadpressure switch
Pilot operatedcheck valve with
needle valve
Hand pump
Bi-directionalvariable speed motor
Brake
Solenoid operated2 position 3 waydirectional valve
Orificewith size
Proportionalsolenoid valve
Shuttle valve
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March 2005Section 6 • Schematics
REV B
6 - 92 GS-2668 RT • GS-3268 RT Part No. 52302
Hydraulic Schematic(before serial number 35557)Part 1 of 2
6.5 gpm24.6 L/min
6.5 gpm24.6 L/min
E 25 psi1.7 bar
1500 psi103.4 bar
3500 psi241.3 bar
P2
P1
S2S1
STEER CYLINDER
RIGHTLEFT
O
2 gpm7.5 L/min
Q
V
R
E
JTEST 2
X
TEST 1
I
X
Y3 Y4
HYDRAULIC TANK
FUNCTIONMANIFOLD
HS0027JHS0032B
IN OUT
RIGHTFRONTOUTRIGGER
RIGHTREAROUTRIGGER
LEFTREAR
OUTRIGGER
LEFTFRONT
OUTRIGGER
Y36
Y33
Y35
Y34CD
CB CA
CC
0.063 in1.6 mm
2000 psi137.8 bar
Y39
Y44
BA
Y40
BD
BBBC
MANIFOLDOUTRIGGER
(OPTION)OUTRIGGERS
BE
BB RR
V1V2
C1C2
VALVECOUNTERBALANCE
3000 psi207 bar4.5:1
MANIFOLD
3000 psi206.8 bar
4.5 gpm17 L/min
GENERATORMANIFOLD
(OPTION)GENERATOR
Y29
AB
AC
AD
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March 2005 Section 6 • Schematics
REV B
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 93
Hydraulic Schematic(before serial number 35557)
Part 2 of 2
P
K
GS-3268:2000 psi / 137.8 barGS-2668:3500 psi / 241.3 bar
Y8
T
FH
Y9
G
241.3 bar
3500 psi
M2A M3A M1A M4A
RIGHTFRONT
M3B M2B M4B M1B
S
Y W X
C
Z
U
0.035 in89 mm
M
A B
L
NY6 Y5 Y6A Y5A
Y1A Y1B
Y2
Y1
FUNCTIONMANIFOLD
D 5 psi0.35 bar
AA 5 psi0.35 bar
LEFTFRONT
RIGHTREAR
LEFTREAR
HS0027J
LIFTCYLINDER
A I
LIFT
Y10
Y7
Y10A
Y7A
0.059 in1.5 mm
AJ
0.059 in1.5 mm
AJ
PLATFORMOVERLOAD(OPTION)
COM N.O.
AK
UPPERLIFT CYLINDER
(GS-3268)
B1HP
AH
B1HP
BRAKE RELEASEMANIFOLD
AE
AF
A I AG
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March 2005Section 6 • Schematics
REV A
6 - 94 GS-2668 RT • GS-3268 RT Part No. 52302
Hydraulic Schematic(from serial number 35557 to 40484)Part 1 of 2
6.5 gpm24.6 L/min
6.5 gpm24.6 L/min
E 25 psi1.7 bar
IN OUT
1500 psi103.4 bar
3500 psi241.3 bar
P2
P1
S2S1
STEER CYLINDER
RIGHTLEFT
O
2 gpm7.5 L/min
Q
V
R
E
JTEST 2
X
TEST 1
I
X
Y3 Y4
RIGHTFRONTOUTRIGGER
RIGHTREAROUTRIGGER
LEFTREAR
OUTRIGGER
LEFTFRONT
OUTRIGGER
Y36
Y33
Y35
Y34CD
CB CA
CC
2000 psi137.8 bar
BA
MANIFOLDOUTRIGGER
(OPTION)OUTRIGGERS
HYDRAULIC TANK
FUNCTIONMANIFOLD
HS0027JHS0032C
IN-B
OUT-B IN-R
OUT-R
BE
3000 psi207 bar4.5:1
Y39Y40
BD
0.063 in1.6 mm
Y44BB
BC
3000 psi206.8 bar
4.5 gpm17 L/min
GENERATORMANIFOLD
(OPTION)GENERATOR
Y29
AB
AC
AD
![Page 259: Service Manual - Ramirenttuotteet.ramirent.fi/sites/tuotteet.ramirent/files/product... · in this manual and the appropriate Operator's Manual on your machine will result in death](https://reader035.fdocuments.us/reader035/viewer/2022062413/5aad9e347f8b9adb688b4b95/html5/thumbnails/259.jpg)
March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 95
Hydraulic Schematic(from serial number 35557 to 40484)
Part 2 of 2
P
K
GS-3268:2000 psi / 137.8 barGS-2668:3500 psi / 241.3 bar
Y8
T
FH
Y9
G
241.3 bar
3500 psi
M2A M3A M1A M4A
RIGHTFRONT
M3B M2B M4B M1B
S
Y W X
C
Z
U
0.035 in89 mm
M
A B
L
NY6 Y5 Y6A Y5A
Y1A Y1B
Y2
Y1
FUNCTIONMANIFOLD
D 5 psi0.35 bar
AA 5 psi0.35 bar
LEFTFRONT
RIGHTREAR
LEFTREAR
HS0027J
ITEMS Y10 AND Y10A ADDEDAFTER SERIAL NUMBER 38464
LIFTCYLINDER
A I
LIFT
Y10
Y7
Y10A
Y7A
0.059 in1.5 mm
AJ
0.059 in1.5 mm
AJ
PLATFORMOVERLOAD(OPTION)
COM N.O.
AK
UPPERLIFT CYLINDER
(GS-3268)
B1HP
AH
B1HP
BRAKE RELEASEMANIFOLD
AE
AF
A I AG
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March 2005Section 6 • Schematics
REV A
6 - 96 GS-2668 RT • GS-3268 RT Part No. 52302
Hydraulic Schematic(from serial number 40485 to GS6804-43183)Part 1 of 2
6.5 gpm24.6 L/min
6.5 gpm24.6 L/min
E 25 psi1.7 bar
1500 psi103.4 bar
3500 psi241.3 bar
P2
P1
S2S1
STEER CYLINDER
RIGHTLEFT
O
2 gpm7.5 L/min
Q
V
R
E
JTEST 2
X
TEST 1
I
X
Y3 Y4
RIGHTFRONTOUTRIGGER
RIGHTREAROUTRIGGER
LEFTFRONT
OUTRIGGER
Y36Y35
Y34
CB CA
CC
(OPTION)OUTRIGGERS
HYDRAULIC TANK
FUNCTIONMANIFOLD
HS0027LHS0032D
IN OUT
2000 psi137.8 bar
BA
MANIFOLDOUTRIGGER
IN-B
OUT-B IN-R
OUT-R
Y39Y40
BD
0.063 in1.6 mm
Y44BB
BC
LEFTREAR
OUTRIGGER
Y33CD
3000 psi206.8 bar
4.5 gpm17 L/min
GENERATORMANIFOLD
(OPTION)GENERATOR
Y29
AB
AC
AD
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 97
Hydraulic Schematic(from serial number 40485 to GS6804-43183)
Part 2 of 2
LIFTCYLINDER
A I
LIFT
P
K
GS-3268:2000 psi / 137.8 barGS-2668:3500 psi / 241.3 bar
Y10
Y7
Y10A
Y7A
0.059 in1.5 mm
AJ
0.059 in1.5 mm
AJ
Y8
T
FH
Y9
G
241.3 bar
3500 psi
M2A M3A M1A M4A
RIGHTFRONT
M3B M2B M4B M1B
S
Y W X
C
Z
U
0.035 in89 mm
M
A B
L
NY6 Y5 Y6A Y5A
Y1A Y1B
Y2
Y1
FUNCTIONMANIFOLD
D 5 psi0.35 bar
AA 5 psi0.35 bar
ITEMS D AND AA CHANGEDTO 200 PSI / 13.8 BAR
AFTER SERIAL NUMBER 40958
PLATFORMOVERLOAD(OPTION)
COM N.O.
AK
UPPERLIFT CYLINDER
(GS-3268)
LEFTFRONT
RIGHTREAR
LEFTREAR
HS0027L
B1HP
AH
B1HP
BRAKE RELEASEMANIFOLD
AE
AF
A I AG
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March 2005Section 6 • Schematics
REV A
6 - 98 GS-2668 RT • GS-3268 RT Part No. 52302
Hydraulic Schematic(after serial number GS6804-43183)Part 1 of 2
6.5 gpm24.6 L/min
6.5 gpm24.6 L/min
E 25 psi1.7 bar
1500 psi103.4 bar
3500 psi241.3 bar
P2
P1
S2S1
STEER CYLINDER
RIGHTLEFT
O
2 gpm7.5 L/min
Q
V
R
E
JTEST 2
X
TEST 1
I
X
Y3 Y4
HYDRAULIC TANK
FUNCTIONMANIFOLD
HS0027MHS0032D
RIGHTFRONTOUTRIGGER
RIGHTREAROUTRIGGER
LEFTFRONT
OUTRIGGER
Y36Y35
Y34
CB CA
CC
(OPTION)OUTRIGGERS
IN OUT
2000 psi137.8 bar
BA
MANIFOLDOUTRIGGER
IN-B
OUT-B IN-R
OUT-R
Y39Y40
BD
0.063 in1.6 mm
Y44BB
BC
LEFTREAR
OUTRIGGER
Y33CD
3000 psi206.8 bar
4.5 gpm17 L/min
GENERATORMANIFOLD
(OPTION)GENERATOR
Y29
AB
AC
AD
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March 2005 Section 6 • Schematics
REV A
Part No. 52302 GS-2668 RT • GS-3268 RT 6 - 99
Hydraulic Schematic(after serial number GS6804-43183)
Part 2 of 2
LIFTCYLINDER
LIFT
P
K
GS-3268:2000 psi / 137.8 barGS-2668:3500 psi / 241.3 bar
Y10
Y7
Y10A
Y7A
0.059 in1.5 mm
AJ
0.059 in1.5 mm
AJ
Y8
T
FH
Y9
M2A M3A M1A M4A
RIGHTFRONT
M3B M2B M4B M1B
S
Y W X
C
Z
U
0.035 in89 mm
M
A B
L
N
G
241.3 bar
3500 psi
Y6 Y5 Y6A Y5A
Y1A Y1B
Y2
Y1
FUNCTIONMANIFOLD
D 200 psi13.8 bar
AA
PLATFORMOVERLOAD(OPTION)
COM N.O.
AK
UPPERLIFT CYLINDER
(GS-3268)
LEFTFRONT
RIGHTREAR
LEFTREAR
HS0027M
B1
BRAKE RELEASEMANIFOLD
HANDPUMP
MANUALRELEASE
BR
AK
E
BHP
AG
200 psi13.8 bar
A I A I
AH
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March 2005Section 6 • Schematics
6 - 100 GS-2668 RT • GS-3268 RT Part No. 52302
This page intentionally left blank.
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Dis
trib
ute
d B
y:
California Proposition 65
WARNINGWARNINGThe exhaust from this product contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.
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Se
rv
ice
Ma
nu
al
GS
-26
68
RT
&G
S-3
26
8R
T
Part No.
52302
Rev D