Terex Genie GS-3369 BE Service Manual
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Terex Genie GS-3369 BE Service Manual

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Service Manual
GS-2669 BE
GS-3369 BE
GS-4069 BE
Part No. 1257106
Rev A3
May 2015

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  • Page 1 Service Manual GS-2669 BE GS-3369 BE GS-4069 BE Part No. 1257106 Rev A3 May 2015...

  • Page 2: Introduction

    Unrestricted with proper operation, inspection and First Edition, First Printing scheduled maintenance. Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GS” is a trademark of Terex South Dakota, Inc. GS-2669 BE • GS-3369 BE • GS-4069 BE...

  • Page 3: Revision History

    May 2015 Service Manual Introduction Revision History Revision Date Section Procedure / Schematic Page / Description 7/2014 New release 12/2014 Repair Added 12-2, Platform Overload Recovery 4/2015 Maintenance Repair 3-5, 7-2 Schematics All Electrical and Hydraulic 5/2015 Repair Reference Examples: Section –...
  • Page 4 Service Manual May 2015 Introduction Revision History Revision Date Section Procedure / Page / Description Reference Examples: Section – Maintenance, B-3 Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 5: Serial Number Legend

    May 2015 Service Manual Introduction Serial Number Legend 1 model 2 model year 3 facility code (for models manufactured in multiple facilities) 4 sequence code 5 serial label (stamped on chassis) 6 serial number (inside compartment) Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...

  • Page 6: Safety Rules

    Service Manual May 2015 Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
  • Page 7 May 2015 Service Manual Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 8: Table Of Contents

    May 2015 Table of Contents Introduction Introduction ......................ii Important Information ....................ii Find a Manual for this Model ................... ii Revision History ..................... iii Serial Number Legend ................... v Section 1 Safety Rules ......................vi General Safety Rules ..................... vi Section 2 Specifications .......................
  • Page 9 May 2015 Table of Contents Section 3 Scheduled Maintenance Procedures ............... 13 Introduction ......................13 Pre-Delivery Preparation Report ................17 Maintenance Inspection Report................19 Checklist A Procedures ..................21 A-1 Inspect the Manuals and Decals..............21 A-2 Perform Pre-operation Inspection ..............22 A-3 Perform Function Tests .................
  • Page 10 May 2015 Table of Contents Checklist C Procedures ..................36 C-1 Test the Platform Overload System (if equipped) ......... 36 C-2 Down Limit Switch Descent Delay (if equipped) ........... 37 Check the Down Limit Switch Rocker Arm Orientation (if equipped) ..... 37 Check the Descent Delay Function ..............
  • Page 11 May 2015 Table of Contents Section 4 Repair Procedures ..................... 45 Introduction ......................45 Platform Controls ....................47 Operational Indicator Codes ................47 1-1 Circuit Board....................48 1-2 Joystick ......................49 1-3 Platfrom Controls Alarm ................. 49 1-4 Platfrom Emergency Stop Button ..............50 Platform Components ..................
  • Page 12 May 2015 Table of Contents Ground Controls ....................70 5-1 Software Revision Level ................71 5-2 Machine Setup ....................72 5-3 Auxiliary Platform Lowering ................73 5-4 Level Sensor - Models without Outriggers ............. 73 5-5 Level Sensor - Models with Outriggers ............76 5-6 Service Override Mode ..................
  • Page 13 May 2015 Table of Contents Fuel and Hydraulic Tanks .................. 98 8-1 Fuel Tank ....................... 98 8-2 Hydraulic Tank ....................99 Steer Axle Components ................... 100 9-1 Yoke Assembly .................... 100 9-2 Steer Cylinder ....................102 9-3 Tie Rod ......................102 9-4 Oscillate Cylinder ..................
  • Page 14 May 2015 Table of Contents Section 5 Fault Codes ....................... 125 Introduction ......................125 Operation Indicator Codes (OIC) ............... 130 Diagnostic Trouble Codes (DTC) ............... 130 Troubleshooting "HXXX" and "PXXX" Faults ............. 131 Fault Inspection Procedure ................132 Type "HXXX" Faults ................... 134 Type "PXXX"...
  • Page 15 May 2015 Table of Contents Section 6 Schematics ......................147 Introduction ......................147 Electrical Component and Wire Color Legends ..........148 Hydraulic Component Legend ................151 Electrical Symbols Legend ................. 152 Hydraulic Symbols Legend ................. 153 Limit Switch Legend ................... 154 Charger Interlock ....................
  • Page 16 May 2015 Table of Contents This page intentionally left blank GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 17: Specifications

    May 2015 Service Manual Specifications Section 2 Specific ati ons Machine Specifications Castle nut (steer end) Castle nut torque 35 ft-lbs Fluid capacities 47.5 Nm Hydraulic tank 16.5 gallons Non-marking, foam filled, RT (maximum fill capacity) 62.5 liters Tire size 26 x 12D380 Hydraulic system without outriggers 16.5 gallons...

  • Page 18: Performance Specifications

    Service Manual May 2015 Specifications Performance Specifications Hydraulic Specifications Drive speed, maximum Hydraulic Fluid Specifications Platform stowed 4.5 mph Genie specifications require hydraulic oils which are Forward direction 7.2 km/h designed to give maximum protection to hydraulic 40 ft / 6.1 sec systems, have the ability to perform over a wide 12.2 m / 6.1 sec temperature range, and the viscosity index should...
  • Page 19 May 2015 Service Manual Specifications Chevron Rando HD Premium Oil Do not top off with incompatible hydraulic fluids. Hydraulic fluids MV Fluid Properties may be incompatible due to the differences in base additive ISO Grade chemistry. When incompatible Viscosity index fluids are mixed, insoluble materials may form and deposit Kinematic Viscosity...
  • Page 20 Service Manual May 2015 Specifications Continued use of Chevron 5606A hydraulic fluid, or equivalent, when ambient temperatures are consistently above 32°F / 0°C may result in component damage Petro-Canada Environ MV 46 Fluid Properties ISO Grade Viscosity index Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 104°F / 40°C 44.4...

  • Page 21: Hydraulic Component Specifications

    May 2015 Service Manual Specifications Hydraulic Component Manifold Component Specifications Specifications Drive Pump Plug torque Type gear pump SAE No. 4 13 ft-lbs / 18 Nm Displacement 0.4 cu in SAE No. 6 18 ft-lbs / 24 Nm 6 cc SAE No.

  • Page 22: Battery Specifications

    Service Manual May 2015 Specifications Battery Specifications T105 Type 6V DC Quantity Capacity 225 AH Reserve capacity @ 25A rate 447 minutes Reserve capacity @ 75A rate 115 minutes Weight, each 63 lbs / 29 kg Weight (tray with batteries) 504 lbs / 229 kg T145 Type...

  • Page 23: Kohler Kd350 Engine Specifications

    May 2015 Service Manual Specifications Kohler KD350 Engine Fuel injection system Injection pump Direct Displacement 21.3 cu in Fuel requirement 0.4 liters For fuel requirements, refer to the engine Operator Number of cylinders Manual for your engine. Bore and Stroke 3.3 x 2.6 inches Battery 82 x 66 mm...

  • Page 24: Hydraulic Hose And Fitting Torque Specifications

    Service Manual May 2015 Specifications SAE O-ring Boss Port Hydraulic Hose and Fitting Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be 23 ft-lbs / 31.2 Nm...

  • Page 25: Torque Procedure

    May 2015 Service Manual Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to hand tight, Replace the O-ring.
  • Page 26 Service Manual May 2015 Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.

  • Page 27: Sae And Metric Fasteners Torque Charts

    May 2015 Service Manual Specifications Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...
  • Page 28 Service Manual May 2015 This page intentionally left blank. GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 29: Scheduled Maintenance Procedures

    May 2015 Service Manual Scheduled Maintenance Procedures Section 3 Machine Configuration: Schedul ed Mai ntenance Pr ocedures  Unless otherwise specified, perform each procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed ...
  • Page 30 Service Manual May 2015 Scheduled Maintenance Procedures About This Section This section contains detailed procedures for each scheduled maintenance inspection. Each procedure includes a description, safety warnings and step-by-step instructions. Symbols Legend Safety alert symbol—used to alert personnel to potential personal injury hazards.
  • Page 31 May 2015 Service Manual Scheduled Maintenance Procedures Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in this The pre-delivery preparation report contains manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.
  • Page 32 Service Manual May 2015 This page intentionally left blank. GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 33: Pre-Delivery Preparation Report

    May 2015 Service Manual Pre-Delivery Preparation Report Fundamentals Instructions It is the responsibility of the dealer to perform the Use the operator’s manual on your machine. Pre-delivery Preparation. The Pre-delivery Preparation consists of The Pre-delivery Preparation is performed prior to completing the Pre-operation Inspection, the each delivery.
  • Page 34 Service Manual May 2015 This page intentionally left blank. GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 35: Maintenance Inspection Report

    May 2015 Service Manual Maintenance Inspection Report Model Y N R Y N R Checklist A Checklist C Inspect the manuals Test platform Serial number and decals overload (if equipped) Down limit switch Pre-operation Date inspection Hydraulic tank cap Function tests Engine maintenance Hour meter Engine maintenance...
  • Page 36 Service Manual May 2015 This page intentionally left blank. GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 37: Checklist A Procedures

    May 2015 Service Manual Checklist A Procedures Open the operator's manual to the decals inspection section. Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes Result: The machine is equipped with all first.

  • Page 38: Perform Pre-Operation Inspection

    Service Manual May 2015 Checklist A Procedures Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes performed every 8 hours or daily, whichever comes first.

  • Page 39: Perform Engine Maintenance

    May 2015 Service Manual Checklist A Procedures Perform Engine Maintenance Test the Oscillate Axle Engine specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes performed every 8 hours or daily, whichever comes first.

  • Page 40: Perform 30 Day Service

    Service Manual May 2015 Checklist A Procedures Perform 30-Day Service Perform Engine Maintenance The 30-day maintenance procedure is a onetime The 50 hour maintenance procedure is a one time procedure to be performed after the first 30 days or sequence of procedures to be performed after the 40 hours of usage.

  • Page 41: Replace The Drive Hub Oil

    May 2015 Service Manual Checklist A Procedures Replace the Drive Hub Oil Drive hub specifications require that this one-time procedure be performed after the first 150 hours of usage. After this interval, refer to the maintenance checklist for continued scheduled maintenance. Replacing the drive hub oil is essential for good machine performance and service life.

  • Page 42: Checklist B Procedures

    Service Manual May 2015 Checklist B Procedures Check the ambient air temperature and adjust the specific gravity reading for each cell as Inspect the Batteries follows: • Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. Genie specifications require that this procedure be •...
  • Page 43 May 2015 Service Manual Checklist B Procedures Check the ambient air temperature and adjust the specific gravity reading for each cell as follows: • Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. •...

  • Page 44: Inspect The Electrical Wiring

    Service Manual May 2015 Checklist B Procedures Inspect the following areas for burnt, chafed, corroded pinched and loose wires: Inspect the Electrical Wiring • In the rear axle: drive motors limit switches Genie specifications require that this procedure be • Hydraulic box: performed every 250 hours or quarterly, whichever comes first.

  • Page 45: Inspect The Tires, Wheels And Castle Nut Torque

    May 2015 Service Manual Checklist B Procedures Inspect the Tires, Wheels and Perform Engine Maintenance Castle Nut Torque Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Genie specifications require that this procedure be first. performed every 250 hours or quarterly, whichever comes first.

  • Page 46: Test The Emergency Stop

    Service Manual May 2015 Checklist B Procedures Test the Emergency Stop Test the Key Switch Genie requires that this procedure be performed Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes first.

  • Page 47: Test The Automotive-Style Horn (If Equipped)

    May 2015 Service Manual Checklist B Procedures Test the Automotive-style Horn Test the Drive Brakes (if equipped) Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Genie specifications require that this procedure be first. performed every 250 hours or quarterly, whichever A functioning horn is essential to safe machine comes first.

  • Page 48: Test The Drive Speed - Stowed Position

    Service Manual May 2015 Checklist B Procedures B-10 Test the Drive Speed – Stowed Test the Drive Speed - Raised Position Position Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.

  • Page 49: Check The Electrical Contactor

    May 2015 Service Manual Checklist B Procedures B-11 B-12 Check the Electrical Contactor Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Maintaining the electrical contactor in good comes first.

  • Page 50: Inspect The Fuel And Hydraulic Tank Cap Venting Systems

    Service Manual May 2015 Checklist B Procedures B-13 Using a mild solvent, carefully wash the cap venting system. Dry using low pressure Inspect the Fuel and Hydraulic compressed air. Repeat this procedure Tank Cap Venting Systems beginning with step 2. Install the fuel tank cap onto the fuel tank.

  • Page 51: Check The Drive Hub Oil Level And Fastener Torque

    May 2015 Service Manual Checklist B Procedures B-14 Apply pipe thread sealant to the plugs and install the plugs. Check the Drive Hub Oil Level and Fastener Torque Repeat steps 1 through 4 for the other drive hub. Check the torque of the drive hub mounting bolts.

  • Page 52: Checklist C Procedures

    Service Manual May 2015 Checklist C Procedures Test the Platform Overload System (if equipped) Genie specifications require that this procedure be performed every 500 hours or six months, whichever comes first OR when the machine fails to lift the maximum rated load. Testing the platform overload system regularly is essential to safe machine operation.

  • Page 53: Down Limit Switch Descent Delay (If Equipped)

    May 2015 Service Manual Checklist C Procedures Lower the platform onto the safety arm. Down Limit Switch Descent Delay Turn the key switch to the off position. (if equipped) 10 Securely install the limit switch to the lower slider channel. Genie specifications require that this procedure be 11 Turn the key switch to ground control and fully performed every 500 hours or six months,...

  • Page 54: Check The Descent Delay Function

    Service Manual May 2015 Checklist C Procedures Chec k the Descent Del ay F uncti on Check the Descent Delay Function Replace the Hydraulic Tank Breather Cap - Models with Pull out the red Emergency Stop button to the Optional Hydraulic Oil on position at the ground controls.

  • Page 55: Perform Engine Maintenance

    May 2015 Service Manual Checklist C Procedures Perform Engine Maintenance Engine specifications require that this procedure be performed every 500 hours or annually, whichever comes first. • Fuel tank • Oil level • Oil filter • Fuel filter • Rocker arm •...

  • Page 56: Checklist D Procedures

    Service Manual May 2015 Checklist D Procedures Replace the Drive Hub Oil Check Scissor Arm Wear Pads and Slider Blocks Genie specifications require that this procedure be performed every 1000 hours or annually, Genie specifications require that this procedure be whichever comes first.

  • Page 57: Test The Function Pump

    May 2015 Service Manual Checklist D Procedures At the ground controls, record the time it takes to fully raise the platform. Test the Function Pump Result: The time to fully elevate the platform is at or less than the table shown below. The efficiency of the function pump is good.

  • Page 58: Checklist E Procedures

    Service Manual May 2015 Checklist E Procedures Push in the red Emergency Stop button to the off position. Test or Replace the Hydraulic Oil Tag and disconnect the harnesses from the ground control box and the contactor box. Remove the ground control box and fuse box Genie specifications require that this procedure be retaining fasteners and set aside.

  • Page 59: Grease The Steer Axle Wheel Bearings

    May 2015 Service Manual Checklist E Procedures 12 Install the drain plug using thread sealer on the threads. Grease the Steer Axle Wheel 13 Install the suction strainer using thread sealer Bearings on the threads. 14 Install the hydraulic tank onto the machine. 15 Secure the tank with the tank strap.
  • Page 60 Service Manual May 2015 Checklist E Procedures Check for wheel bearing wear by attempting to 13 Place the hub on a flat surface and gently pry move the wheel hub side to side, then up and the bearing seal out of the hub. Remove the Result:  There is no side to side or up and down.

  • Page 61: Repair Procedures

    May 2015 Service Manual Repair Procedures Machine Configuration: Section 4 Repair Pr oc edures  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed ...
  • Page 62 Service Manual May 2015 Repair Procedures About This Section Symbols Legend Safety alert symbol—used to alert Most of the procedures in this section should only personnel to potential personal be performed by trained service professional in a injury hazards. Obey all safety suitably equipped workshop.

  • Page 63: Platform Controls

    May 2015 Service Manual Platform Controls Platform controls Operati onal Indic ator Codes Operational Indicator Codes The platform controls are used to operate the These codes are generated by the electrical machine from the platform. system to indicate machine operating status. During normal operation a code will appear in the Activating a function button sends a signal to the platform controls LED readout if a condition such...

  • Page 64: Circuit Board

    Service Manual May 2015 Platform Controls Carefully disconnect all wire harness connectors from the platform controls circuit Circuit Board board. Electrocution/burn hazard. How to Remove the Platform Contact with electrically charged Controls Circuit Board circuits could result in death or serious injury.

  • Page 65: Joystick

    May 2015 Service Manual Platform Controls Joystick Platform Controls Alarm How to Remove the Joystick How to Remove the Platform Controls Alarm Push in the red Emergency Stop button to the off position at both the ground and platform Push in the red Emergency Stop button to the controls.

  • Page 66: Platfrom Emergency Stop Button

    Service Manual May 2015 Platform Controls Platform Emergency Stop Button How to Remove the Platform Controls Emergency Stop Button Push in the red Emergency Stop button to the off position at both the ground and platform controls. Disconnect the platform controls from the control cable at the platform.

  • Page 67: Platform Components

    May 2015 Service Manual Platform Components Remove the cover from the AC outlet. Tag and disconnect the wiring from the outlet. Platform Electrocution/burn hazard. Contact with electrically charged How to Remove the Platform circuits could result in death or serious injury. Remove all rings, Bodily injury hazard.

  • Page 68: Platform Extension Deck

    Service Manual May 2015 Platform Components Carefully lift the platform enough to clear the platform pivot. Platform Extension Deck 10 Slide the platform towards the non-steer end of the machine until the slider blocks are How to Remove the Platform visible underneath the slider block channel.
  • Page 69 May 2015 Service Manual Platform Components Release the four rail spacers by pulling the Carefully slide the platform extension out and retaining pin and turn them in a downward away from the platform and place it on a position. structure capable of supporting it. Crushing hazard.

  • Page 70: Scissor Components

    Service Manual May 2015 Scissor Components Steer End Non-steer End 1 Platform pivot 10 Chassis pivot 2 Number 3 outer arm 11 Slider block (Qty. 2) 3 Lift cylinder rod-end pivot pin 12 Number 3 inner arm 4 Number 3 pivot pin (steer end) 13 Number 3 center pivot pin (Qty.

  • Page 71: Scissor Assembly, Gs-2669 Be

    May 2015 Service Manual Scissor Components Using a suitable supporting device, attach a strap to the rod end of the lift cylinder. Do not Scissor Assembly, GS-2669 BE apply pressure. Remove the lift cylinder rod end pivot pin How to Disassemble the Scissor retaining fasteners.
  • Page 72 Service Manual May 2015 Scissor Components 13 Remove the retaining fasteners from the 20 Remove the two carriage bolts that secure the number 2 pivot pins. inner arm and chassis pivot to the steer end of the drive chassis. Note: Do not remove the external snap ring. 21 Move the linkage towards the non-steer end of 14 Using a soft metal drift, remove the pivot pins the machine until the slider feet are clear of...
  • Page 73 May 2015 Service Manual Scissor Components Steer End Non-steer End 1 Platform pivot 13 Chassis pivot 2 Number 4 center pivot pin (Qty. 2) 14 Slider block (Qty. 2) 3 Number 4 pivot pin (steer end) 15 Number 4 inner arm 4 Number 3 center pivot pin (Qty.

  • Page 74: Scissor Assembly, Gs-3369 Be

    Service Manual May 2015 Scissor Components Using an overhead lifting device attach a 4 hook sling chain to the ends of the number Scissor Assembly, GS-3369 BE 4 inner arm. Make the chains tight but do not apply lifting pressure. How to Disassemble the Scissor Crushing hazard.
  • Page 75 May 2015 Service Manual Scissor Components 13 Remove the retaining fasteners from the 21 Tag and disconnect the hydraulic hoses from number 3 pivot pins. the lift cylinder. Plug the hoses and cap the fittings. Note: Do not remove the external snap ring. Bodily injury hazard.
  • Page 76 Service Manual May 2015 Scissor Components Separate the link sets: Using an overhead lifting device attach a 4 hook sling chain to the ends of the inner arm. Make the chains tight but do not apply lifting pressure. Crushing hazard. The linkage assembly could become unbalanced and fall if not properly supported when...
  • Page 77 May 2015 Service Manual Scissor Components Steer End Non-steer End 1 Platform pivot 16 Slider block (Qty. 2) 2 Number 5 center pivot pin (Qty. 2) 17 Number 5 inner arm 3 Number 5 pivot pin (steer end) 18 Number 5 outer arm 4 Number 4 center pivot pin (Qty.

  • Page 78: Scissor Assembly, Gs-4069 Be

    Service Manual May 2015 Scissor Components Using an overhead lifting device attach a 4 hook sling chain to the ends of the number Scissor Assembly, GS-4069 BE 4 inner arm. Make the chains tight but do not apply lifting pressure. How to Disassemble the Scissor Crushing hazard.
  • Page 79 May 2015 Service Manual Scissor Components 13 Remove the retaining fasteners from the 22 Using a soft metal drift, remove the pivot pin. number 4 pivot pins. 23 Lower the lift cylinder and remove the strap. Note: Do not remove the external snap ring. 24 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 14 Using a soft metal drift, remove the pivot pins...
  • Page 80 Service Manual May 2015 Scissor Components Separate the link sets: 31 Carefully lift the linkage assembly off of the machine and place it on a structure capable of Using an overhead lifting device attach a supporting it. 4 hook sling chain to the ends of the inner 32 Tag and disconnect the harness from the arm.

  • Page 81: Wear Pads

    May 2015 Service Manual Scissor Components Remove the fasteners securing the ladder to the chassis. Remove the ladder from the Wear Pads machine and set aside. Crushing hazard. The ladder How to Replace the Scissor Arm could fall if not properly Wear Pad supported when the fasteners are removed from the machine.
  • Page 82 Service Manual May 2015 Scissor Components Remove the retaining fasteners from the slider Using a hard rubber mallet, secure the upper feet pivot pins and set aside. and lower wear pads to the slider feet. 1 upper wear pads 1 Slider foot assembly 2 slider foot 2 pivot pin 3 lower wear pad...

  • Page 83: Lift Cylinders

    May 2015 Service Manual Scissor Components Lift Cylinders The lift cylinders are single acting hydraulic cylinders. The GS-2669 and GS-3369 uses one lift cylinder; the GS-4069 uses two. Each lift cylinder is equipped with a check valve to prevent movement in the event of a hydraulic line failure.
  • Page 84 Service Manual May 2015 Scissor Components Disassemble the scissor assembly. Refer to GS-4069 BE: Repair Procedure, How to Disassemble the Scissor Assembly. Bodily injury hazard. This procedure requires specific repair skills, lifting equipment and a suitable workshop. Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage.

  • Page 85: Engines

    May 2015 Service Manual Engines Note: Always use pipe thread sealant when installing a new switch. Oil Pressure Switch The engine oil pressure switch is a normally open switch. The switch contacts close at approximately 7 psi / 0.48 bar. If the oil pressure drops below the switch point, the contacts open and the engine will shut off to prevent damage.

  • Page 86: Ground Controls

    Service Manual May 2015 Ground Controls Ground Controls The ground controls, used to operate the machine from the ground, can also be used to tune the performance of the machine. The ground controls consist of an Electronic Control Module (ECM), emergency stop button, key switch and circuit breaker.

  • Page 87: Software Revision Level

    May 2015 Service Manual Ground Controls Press the ground control scroll down button. Software Revision Level Result: The ground control LCD display will indicate the software revision and hour meter information. After 5 seconds, the ground How to Determine the Software controls LCD display will display machine Revision Level model and hour meter information again.

  • Page 88: Machine Setup

    Service Manual May 2015 Ground Controls Press and hold the ground control scroll up and scroll down buttons. Machine Setup How to Setup the Machine from Ground Controls The ground controls can be used to setup the machine parameters from the ground. Features that can be adjusted from the ground controls include machine Model, Options and Speed setup.

  • Page 89: Auxiliary Platform Lowering

    May 2015 Service Manual Ground Controls Auxiliary Platform Lowering Level Sensor - Models without Outriggers In the event of a main power failure, activating the auxiliary enable and auxiliary platform lowering The Electronic Control Module (ECM) is toggle switches at the ground controls will lower the programmed to deactivate the lift and drive platform.
  • Page 90 Service Manual May 2015 Ground Controls Locate the level sensor in the ground controls compartment. 1 ground control box 2 level sensor 1 "Y" indicator 2 level sensor Tag and disconnect the level sensor wire harness from the chassis wire harness. 3 "X"...
  • Page 91 May 2015 Service Manual Ground Controls Center a lifting jack under the drive chassis at 21 Place a 2.25 x 10 x 10 inch / 5.72 x 25 x 25 cm the ground controls side of the machine. thick steel block under both wheels at the ground controls side of the machine.

  • Page 92: Level Sensor - Models With Outriggers

    Service Manual May 2015 Ground Controls Tag and disconnect the wire harness from the level sensor. Level Sensor - Models with Outriggers The Electronic Control Module (ECM) is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor.
  • Page 93 May 2015 Service Manual Ground Controls Install the new level sensor onto the machine Connect the wire harness to the level sensor. with the "X" on the level sensor base towards Adjust the level sensor retaining fasteners the steer end of the machine. Install and until the bubble in the top of the level sensor is tighten the level sensor retaining fasteners.

  • Page 94: Service Override Mode

    Service Manual May 2015 Ground Controls Turn the key switch to the ground controls position and pull out the red Emergency Stop Service Override Mode button to the on position at the platform controls. The Electronic Control Module (ECM) is programmed with a Service Override mode.
  • Page 95 May 2015 Service Manual Ground Controls At the ground controls, use the Scroll Down button to scroll to SVC Override. Result: The ground controls LCD display will show the following: Press the Enter button. Result: The ground controls LCD display will show the following: Press the Enter button.

  • Page 96: Hydraulic Pump

    Service Manual May 2015 Hydraulic Pump How to R emove the Hydr aulic Pump How to Remove the Hydraulic Pump Hydraulic Pump Tag, disconnect and plug the hydraulic hoses The hydraulic pump is a single section, gear-type on the pump. Cap the fittings on the pump. pump.

  • Page 97: How To Calibrate The Hydraulic Pump

    May 2015 Service Manual Hydraulic Pump How to C alibr ate the Hy draulic Pum p How to Calibrate the Hydraulic Release the Scroll Up and Scroll Down buttons after the ground controller powers up. Pump At the ground controls, use the Scroll Up or Turn the key switch to the ground controls Scroll Down buttons to scroll to Select Option.
  • Page 98 Service Manual May 2015 Hydraulic Pump Result: The ground controls LCD displays the 10 Press the Enter button. following screen. Calibration data is within Result: The ground controls LCD display will range. show the following: Note: The screen will return to the options screen 11 Press and Hold the Enter button.

  • Page 99: Manifolds

    May 2015 Service Manual Manifolds Function Manifold Components The function manifold is located inside the hydraulic compartment. Index Schematic Description Function Torque Item Check valve Oscillate circuit 20 ft-lbs / 27 Nm Solenoid Valve, 2 position 3 way Oscillate / Accumulator 20 ft-lbs / 27 Nm Orifice Relief valve...
  • Page 100 Service Manual May 2015 Manifolds GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 101: Valve Adjustments - Function Manifold

    May 2015 Service Manual Manifolds Adjust the internal hex socket. Turn it clockwise to increase the pressure or Valve Adjustments - Function counterclockwise to decrease the pressure. Manifold Install the relief valve cap. Tip-over hazard. Do not adjust How to Adj ust the Sy stem Reli ef Valve How to Adjust the System Relief the relief valve higher than Valve...

  • Page 102: How To Adjust The Oscillate Relief Valve

    Service Manual May 2015 Manifolds How to Adj ust the Oscill ate R elief Valve 10 Remove the pressure gauge. How to Adjust the Oscillate Relief Valve Note: Perform this procedure with the machine in the stowed position and in high torque mode. Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to test port #2 (TP2) on the function manifold.

  • Page 103: How To Adjust The Steer Relief Valve

    May 2015 Service Manual Manifolds How to Adj ust the Steer R elief Valve Remove the pressure gauge. How to Adjust the Steer Relief Valve Note: Perform this procedure with the machine in the stowed position. Connect a 0 to 5000 psi / 0 to 350 bar pressure gauge to test port #1 (TP1) on the function manifold.

  • Page 104: How To Adjust The Platform Up Relief Valve - Models With Platform Overload

    Service Manual May 2015 Manifolds How to Adj ust the Pl atform U p R elief Valve - Models with Platform Ov erload Press and hold the ground control scroll up How to Adjust the Platform Up and scroll down buttons. Relief Valve - Models with Platform Overload Note: Verify the hydraulic oil level is within the top...
  • Page 105 May 2015 Service Manual Manifolds Note: After 1 second the display will return to At the ground controls, use the Scroll Down SELECT OPTION, PLAT. OVERLOAD. button to scroll to SELECT OPTION. Result: The ground controls LCD display will show the following: 10 Press the Scroll Down button to scroll to Down Delay.
  • Page 106 Service Manual May 2015 Manifolds Note: After 1 second the display will return to 19 Locate and disconnect the maximum height SELECT OPTION, DOWN DELAY. limit switch harness. 13 Push in the red Emergency Stop button to the off position. 14 Pull out the red Emergency Stop button to the on position and raise the platform approximately 10 feet / 3 m.
  • Page 107 May 2015 Service Manual Manifolds 24 Using a suitable lifting device, place and 32 Lift the safety arm, move it to the center of the secure the maximum rated load in the center scissor arm and rotate down to a vertical of the platform deck.
  • Page 108 Service Manual May 2015 Manifolds Note: After 1 second the display will return to 44 At the ground controls, use the Scroll Down SELECT OPTION, PLAT. OVERLOAD. button to scroll to SELECT OPTION. Result: The ground controls LCD display will show the following: 48 Press the Scroll Down button to scroll to Down Delay.

  • Page 109: How To Adjust The Platform Up Relief Valve - Models Without Platform Overload

    May 2015 Service Manual Manifolds How to Adj ust the Pl atform U p R elief Valve - Models without Pl atform Overl oad How to Adjust the Platform Up 50 Press the Enter button. Relief Valve - Models without Result: The ground controls LCD display will show the following: Platform Overload...
  • Page 110 Service Manual May 2015 Manifolds Using a suitable lifting device, place and secure the maximum rated load in the center of the platform deck. GS-2669 1500 lbs / 680 kg GS-3369 1000 lbs / 454 kg GS-4069 800 lbs / 363 kg Press and hold the lift function enable button and platform up button.

  • Page 111: Outrigger Manifold Components

    May 2015 Service Manual Manifolds Outrigger Manifold Components The outrigger manifold is located inside the hydraulic compartment. Index Schematic Description Function Torque Item 20-25 ft-lbs / 27-34 Solenoid valve, 3 position 4 way Outriggers extend / retract Part No. 1257106 GS-2669 BE •...

  • Page 112: Valve Coils

    Service Manual May 2015 Manifolds Valve Coil Resistance Specification Valve Coils Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromagnetic force which operates the solenoid...

  • Page 113: How To Test A Coil Diode

    May 2015 Service Manual Manifolds How to T est a Coil Di ode How to Test a Coil Diode Properly functioning coil diodes protect the electrical circuit by suppressing voltage spikes. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.

  • Page 114: Fuel And Hydraulic Tanks

    Service Manual May 2015 Fuel and Hydraulic Tanks Remove the cooling fan and fan shroud and set aside. Fuel Tank Remove the fuel tank cover above the fuel tank. How to Remove the Fuel Tank Disconnect the return line from the top of the fuel tank.

  • Page 115: Hydraulic Tank

    May 2015 Service Manual Fuel and Hydraulic Tanks Tag and disconnect the harnesses from the ground control box. Hydraulic Tank Remove the ground control box from the The primary functions of the hydraulic tank is to machine and set aside. cool, clean and deaerate the hydraulic fluid during Tag, disconnect and plug the hydraulic hoses operation.

  • Page 116: Steer Axle Components

    Service Manual May 2015 Steer Axle Components Left side yoke: Yoke Assembly Remove the retaining fasteners from the tie rod pivot pin. How to Remove the Yoke Chock both sides of the wheels at the non-steer end of the machine. Center a lifting jack under the drive chassis at the steer end of the machine.
  • Page 117 May 2015 Service Manual Steer Axle Components How to Remove a Drive Motor 12 Remove the retaining fastener from the lower yoke king pin. Component damage hazard. 13 Use a small pry bar to remove the king pin. Repairs to the motor should only be performed by an authorized 14 Remove the retaining fastener from the upper dealer.

  • Page 118: Steer Cylinder

    Service Manual May 2015 Steer Axle Components Steer Cylinder Tie Rod How to Remove the Steer How to Remove the Tie Rod Cylinder Remove the rue ring from the clevis pin connecting the tie rod to the right side yoke Note: When removing a hose assembly or fitting, assembly.

  • Page 119: Oscillate Cylinder

    May 2015 Service Manual Steer Axle Components Oscillate Cylinder Oscillate Hoses How to Remove the Oscillate Test the Oscillate Axle Hose Cylinder Routing Note: When removing a hose assembly or fitting, Note: Perform this procedure if the oscillate hoses the O-ring (if equipped) on the fitting and/or hose have been removed or replaced.
  • Page 120 Service Manual May 2015 Steer Axle Components Disconnect the connector with the green/black Turn the key switch to platform control and pull wire from the oscillate right coil (item 2) and out the red Emergency Stop button to the on swap it with the connector with the blue wire position at both the ground and platform from the steer right coil (item 3).

  • Page 121: Steer Angle Sensor

    May 2015 Service Manual Steer Axle Components Remove the tie rod pivot pin retaining fasteners. Steer Angle Sensor How to Replace the Steer Angle Sensor The steer angle sensor, installed on the steer yoke, is monitored by the control system to determine steer angle.
  • Page 122 Service Manual May 2015 Steer Axle Components 10 Remove the steer sensor assembly retaining 12 Pull the sensor harness through the cable fasteners. Remove the steer sensor assembly restraint and sensor bracket. from the yoke. 13 Remove the retaining fasteners that secure 11 Set the spacer plate aside.

  • Page 123: How To Calibrate The Steer Angle Sensor

    May 2015 Service Manual Steer Axle Components How to C alibr ate the Steer Angle Sensor How to Calibrate the Steer Angle 17 Install the steer sensor actuator onto the tie rod pivot pin. Sensor 18 Insert the compression spring into the steer Turn the key switch to the ground controls sensor and push the tie rod pivot pin up until position and pull out the red Emergency Stop...
  • Page 124 Service Manual May 2015 Steer Axle Components Release the Scroll Up and Scroll Down 10 Press the Enter button. buttons after the ground controller powers up. Result: The ground controls LCD display will show the following: At the ground controls, use the Scroll Down button to scroll to SELECT OPTION.
  • Page 125 May 2015 Service Manual Steer Axle Components 13 Press the Enter button. 16 Use the platform drive controller steer function to turn the steer tires fully to the left. Result: The ground controls LCD display will show the following: 17 Press the Enter button. Result: The ground controls LCD display will show the following: Note: If any screens other than the one shown is...

  • Page 126: Non-Steer Axle Components

    Service Manual May 2015 Non-steer Axle Components Remove the axle cover. 10-1 Drive Motors How to Remove a Drive Motor The drive motors are AC powered and are a brushless design requiring very little maintenance. They have built-in speed and temperature sensors which is monitored by the ground controls (GCON).
  • Page 127 May 2015 Service Manual Non-steer Axle Components 11 Using a suitable supporting device, secure the 14 Remove the retaining fasteners that secure rear axle assembly. Do not apply pressure. the drive motor to the drive hub. 15 Support and slide the drive motor shaft out of the drive hub.

  • Page 128: Drive Hub

    Service Manual May 2015 Non-steer Axle Components 10-2 Drive Hub How to Remove a Drive Hub Component damage hazard. Repairs to the drive hub should only be performed by an authorized dealer. 1 axle assembly Remove the drive motor. Refer to Repair 2 o-ring Procedure, How to Remove a Drive Motor.

  • Page 129: Outrigger Components

    May 2015 Service Manual Outrigger Components 11-1 Attach a lifting strap from an overhead crane to the barrel end of the outrigger cylinder for Outrigger Cylinder support. Do not apply any lifting pressure. Remove the outrigger mounting fasteners. How to Remove an Outrigger Slide the outrigger cylinder down and away Cylinder (if equipped) from the machine.

  • Page 130: Outrigger Calibration

    Service Manual May 2015 Outrigger Components 11-2 Press and hold the ground control scroll up and scroll down buttons. Outrigger Calibration The Electronic Control Module (ECM) is programmed to deactivate the drive and steer functions while the outriggers are deployed and activate an alarm when a signal is received from the outrigger level sensor, indicating the outriggers are not deployed or the machine is out of level.
  • Page 131 May 2015 Service Manual Outrigger Components Use the Scroll Up or Scroll Down buttons to scroll to Outriggers. Press the Enter button to select Outriggers. Use the Scroll Up or Scroll Down buttons to scroll to Calibrate Outriggers. 10 Press the Enter button to select Calibrate Outriggers.

  • Page 132: Platform Overload Components

    Service Manual May 2015 Platform Overload Components 12-1 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on Platform Overload System (if position at both ground and platform controls. equipped) Raise the platform approximately 10 feet / 3 m.

  • Page 133: Check The Maximum Height Limit Switch

    May 2015 Service Manual Platform Overload Components Chec k the Maximum H eight Limit Switc h Check the Maximum Height Limit 12 Remove the supporting device from under the platform. Switch 13 Raise the platform to 13 ft / 4 m. Using a suitable lifting device, place a test 14 Lift the safety arm, move it to the center of the weight in the center of the platform floor.
  • Page 134 Service Manual May 2015 Platform Overload Components Lower the platform to the stowed position. Remove the test weight. Limit switch legend 1 down limit switch 2 load sense interrupt limit switch 3 maximum height limit switch GS-2669 BE • GS-3369 BE • GS-4069 BE Part No.

  • Page 135: Platform Overload System Troubleshooting

    May 2015 Service Manual Platform Overload Components Platform Ov erload Sys tem Troubl es hooti ng Platform Overload System Troubleshooting Condition Possible Cause Solution Cannot lift rated load Relief valve set too low Increase relief valve pressure At max. Height with rated load in platform, System needs to be reset Turn off red emergency stop button, pressure switch alarm continues to sound...

  • Page 136: Platform Overload Recovery

    Service Manual May 2015 Platform Overload Components 12-2 Pull out the red Emergency Stop button at the ground controls. Platform Overload Recovery Result: The ground control LCD display will Message show the following. If the ground controls LCD screen displays OL: PLATFORM OVERLOADED, the emergency lowering system has been used while the platform was overloaded.
  • Page 137 May 2015 Service Manual Platform Overload Components Press and hold the scroll down button for 5 seconds. Result: The ground control LCD display will show the following. Press the enter button. Result: The ground control LCD display will show the following. Press the buttons in the following sequence: (down)(down)(up)(enter).

  • Page 138: Battery Charger

    Service Manual May 2015 Battery Charger 13-1 Battery Charger The machine is equipped with 2 battery chargers. The primary charger delivers an output voltage at full power. The boost charger delivers an output voltage at reduce power. If the primary charger is replaced, no adjustments are required unless your machine is equipped with AGM batteries.
  • Page 139 May 2015 Service Manual Battery Charger 1 LED charge indicator 4 selector curve 2 charger interlock connection 5 not used 3 battery connection 6 AC input LED is red during phases I1 and P (bulk charger). (20% battery charged) LED is yellow during phases U and I2. (80% battery charged) LED is green at the end of charge.
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  • Page 141: Fault Codes

    May 2015 Service Manual Fault Codes Section 5 Faul t Codes Before Troubleshooting:  Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine.  Be sure that all necessary tools and test equipment are available and ready for use.

  • Page 142: About This Section

    Service Manual May 2015 Fault Codes About This Section GCON LCD Diagnostic Readout When a malfunction is discovered, the fault code charts in this section will help a service professional pinpoint the cause of the problem. To use this section, basic hand tools and certain pieces of test equipment are required —...
  • Page 143 May 2015 Service Manual Fault Codes Genie SmartLink Diagnostic GCON ECM Connector Layout System This machine is equipped with the Genie SmartLink™ Diagnostic System (GSDS). The GSDS indicates a machine malfunction has happened by displaying Operational Indicator Codes (OIC) and Diagnostic Trouble Codes (DTC). These codes are displayed at the Platform Controls and the Ground Controls.
  • Page 144 Service Manual May 2015 Fault Codes GCON I/O MAP Ground Circuit Function I/O Type Wire Color Controls Pin Number C1 Connector - Gray C1-01 ECM / Logic Power Power Input C1-02 PCON - E-Stop Power Power Output C1-03 PCON - E-Stop Return Power Input C1-04 Link to PCON - CAN HI...
  • Page 145 May 2015 Service Manual Fault Codes C3 Connector - Green C3-01 Not Used C3-02 GCON - Alarm Digital Output WH/RD C3-03 Sensor Power Digital Output C3-04 Automotive Horn Digital Output C3-05 Left Oscillate Limit Switch Digital Input GR/BK C3-06 Right Oscillate Limit Switch Digital Input C3-07 Down Limit Switch - LS6...

  • Page 146: Operation Indicator Codes (Oic)

    Service Manual May 2015 Fault Codes Operation Indicator Codes (OIC) Diagnostic Trouble Codes (DTC) These codes are generated by the electrical These codes are generated by the system to system to indicate machine operating status such indicate that a device or circuit malfunction has as Off-level, Overload Cutout, Chassis Mode been detected in the electrical system.

  • Page 147: Troubleshooting "Hxxx" And "Pxxx" Faults

    May 2015 Service Manual Fault Codes Troubleshooting "HXXX" and "PXXX" Faults The procedure below illustrates typical steps for diagnosing and fixing faults of type "HXXX" and "PXXX". Diagnostic Chart Good 1 Check the faulted device for a short or open circuit. Replace faulted device.

  • Page 148: Fault Inspection Procedure

    Service Manual May 2015 Fault Codes Fault Inspection Procedure Check the device associated with the faulted circuit Disconnect the faulted device connector. Using a multi-meter, measure resistance between the two terminals of the faulted device. Resistance should be as follows. Device Typical Resistance Solenoid Valve, Drive...
  • Page 149 May 2015 Service Manual Fault Codes Disconnect the GCON ECM connectors, C1, C2 and C3. (or C4 if equipped with outriggers). For short to B- type faults, measure resistance between pins J1-7 (ground) and the GCON pin associated with the fault code.

  • Page 150: Type "Hxxx" Faults

    Service Manual May 2015 Fault Codes Type "HXXX" Faults Message on Description Possible Causes Failure Mode Number GCON LCD H001 H001:COILFAULT Short circuit of the platform up • Short circuit in platform up #1 harness. Platform up function PLAT UP1:Bat- #1 circuit to battery negative.
  • Page 151 May 2015 Service Manual Fault Codes Type "HXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD H066 H066:COILFAULT Short circuit of the right rear outrigger • Short circuit in right rear outrigger coil harness. All functions inhibited RR RIGGER:Bat+ coil to battery positive.
  • Page 152 Service Manual May 2015 Fault Codes Type "HXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD H089 H089:COILFAULT Open circuit of the oscillate left • Open circuit in oscillate left harness. All functions inhibited OSC LEFT:Open circuit.

  • Page 153: Type "Pxxx" Faults

    May 2015 Service Manual Fault Codes Type "PXXX" Faults Message on Description Possible Causes Failure Mode Number GCON LCD P001 P001:PWRFAULT Short circuit of the switched power • Short circuit in switched power #1, down limit switch or All functions inhibited. SW PWR:Bat- #1 circuit to battery negative.
  • Page 154 Service Manual May 2015 Fault Codes Type "PXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD P032 P032:COILFAULT Short or open circuit of the left rear • Short or open circuit in left rear brake harness. All functions inhibited.
  • Page 155 May 2015 Service Manual Fault Codes Type "PXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD P046 P046:PWR FAULT Short to battery positive or open • Short or open in engine harness. Engine will not start and circuit of the engine start circuit.

  • Page 156: Type "Uxxx" Faults

    Service Manual May 2015 Fault Codes Type "UXXX" Faults Message on Description Possible Causes Failure Mode Number GCON LCD U001 U001:SWITCHFAULT Short circuit of the GCON main • Short circuit of the GCON main function enable switch. All GCON functions GCON MAIN FTN EN function enable switch at system •...
  • Page 157 May 2015 Service Manual Fault Codes Type "UXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD U033 U033:JSTICKFAULT PCON drive joystick signal is outside • PCON drive joystick is not in neutral position range at All drive and steer OUT OF CAL RANGE acceptable calibration.

  • Page 158: Type "Fxxx" Faults

    Service Manual May 2015 Fault Codes Type "FXXX" Faults Message on Description Possible Causes Failure Mode Number GCON LCD F003 F003:SWITCHFAULT Short circuit of the down limit • Short circuit of the down limit switch circuit. All functions inhibited DOWN LIMIT1:Bat+ #1 switch at system startup.
  • Page 159 May 2015 Service Manual Fault Codes Type "FXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD F049 F049:SENSORFAULT Short circuit of the pump speed • Short circuit of the pump speed sensor. All functions operate. PUMP SPEED:Bat+ sensor to battery positive.
  • Page 160 Service Manual May 2015 Fault Codes Type "FXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD F064 F064:SWITCHFAULT Left axle safety limit switch state not • Short or open circuit of the left axle safety and/or operational All functions inhibited LEFT AXLE:MISM matching the left axle operational...

  • Page 161: Type "Cxxx" Faults

    May 2015 Service Manual Fault Codes Type "CXXX" Faults Message on Description Possible Causes Failure Mode Number GCON LCD C001 C001:GCON ECM GCON ECM CRC check error. • Incorrect software file. All functions inhibited. FAULT TYPE 1 • GCON ECM internal failure. C004 C004:GCON ECM GCON ECM master switch error.
  • Page 162 Service Manual May 2015 Fault Codes Type "CXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD C034 C034:DCON RR ECM Valve driver failure of the right rear • Right rear DCON ECM. Drive functions inhibited. FAULT TYPE 03 drive controller.

  • Page 163: Schematics

    May 2015 Service Manual Schematics Section 6 About This Section Schem atics There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, ...

  • Page 164: Electrical Component And Wire Color Legends

    Service Manual May 2015 Electrical Component and Wire Color Legends Electrical Component Legend Control relay Item Description CR1 = Starter Alternator CR2 = Ignition Battery CR15 = Glow plug B1 = 12V DC Start battery CR60 = Brake release B7 = 48V DC Battery pack CR61 = Key switch Button CR62 = Engine RPM...
  • Page 165 May 2015 Service Manual Electrical Component and Wire Color Legends Resistor Electrical Component Legend (cont.) R1 = 2k ohm Item Description Key switch RCBO Residual current circuit breaker with overload protection (CE / AS) KS1 = Key switch Sensor LED or Light S7 = Digital level sensor (w/o outriggers) L12 = Left front outrigger (option) (platform) S8 = Analog level sensor (w/ outrigger...
  • Page 166 Service Manual May 2015 Electrical Component and Wire Color Legends Electrical Component Legend (cont.) Wire Color Legend Item Description Color Description Blue Valve coil Black Y3 = Steer right / CW Brown Y4 = Steer left / CCW Green Y7 = Platform down Orange Y7A = Platform down (GS-4069 models) Purple...

  • Page 167: Hydraulic Component Legend

    May 2015 Service Manual Hydraulic Component Legend Item Function Item Function 3 position, 4 way directional valve - outrigger Relief valve - main system cylinders extend/retract (option) Relief valve - steer circuit 2 position, 2 way valve - platform down (all Check valve - load sense circuit models) Flow regulator valve - controls flow to the...

  • Page 168: Electrical Symbols Legend

    Service Manual May 2015 Electrical Symbols Legend Battery Motor Horn or alarm Flashing beacon Gauge Circuit breaker with Diode Coil with suppression Fuse with amperage amperage Level sensor Connection - no Circuits crossing no Quick disconnect Power relay terminal connection terminal without outriggers Button...

  • Page 169: Hydraulic Symbols Legend

    May 2015 Service Manual Hydraulic Symbols Legend Orifice with size Check valve Cylinder, double acting Accumulator Pump, prime mover (engine Pump, fixed displacement Pressure switch Needle valve or motor) Solenoid operated Solenoid operated Solenoid operated Solenoid operated 3 position 4 way directional 3 position 5 way 2 position, 3 way directional 2 position 2 way directional...

  • Page 170: Limit Switch Legend

    Service Manual May 2015 Limit Switch Legend 1 left rear outrigger limit switch, LS14 6 right front outrigger limit switch, LS13 left front outrigger limit switch, LS12 (not 2 left axle oscillate limit switches, LSA10S shown) and LSA10SS 7 platform down limit switches, LS6 and 3 right rear outrigger limit switch, LS15 LS6B 4 right axle oscillate limit switches, LSA20S...

  • Page 171: Charger Interlock

    May 2015 Service Manual Charger Interlock Interlock relay (NO), 10A contact Charger not connected to battery or main supply. (Contact open) Charger connected to battery. (Contact closed) Charger connected to battery and main supply. (Contact open) Supply Battery Contact Not connected Not connected Open Not connected...
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  • Page 173 May 2015 Service Manual Contactor Box Layout, All Models...

  • Page 174: Contactor Box Layout, All Models

    Service Manual May 2015 Contactor Box Layout, All Models GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 175: Ground Control Box Layout, All Models

    May 2015 Service Manual Ground Control Box Layout, All Models Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...
  • Page 176 Service Manual May 2015 Ground Control Box Layout, All Models...
  • Page 177 May 2015 Service Manual Platform Control Box Layout, All Models...

  • Page 178: Platform Control Box Layout, All Models

    Service Manual May 2015 Platform Control Box Layout, All Models GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 179: Generator Wiring Diagram, All Models

    May 2015 Service Manual Generator Wiring Diagram, All Models Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...
  • Page 180 Service Manual May 2015 Generator Wiring Diagram, All Models...
  • Page 181 May 2015 Service Manual Electrical Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift, (ANSI / CSA)

  • Page 182: Electrical Schematic, Gs-2669 Be And Gs-3369 Be With 2 Speed Lift, (Ansi / Csa)

    Service Manual May 2015 Electrical Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift, (ANSI / CSA) GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 183: Electrical Schematic, Gs-2669 Be And Gs-3369 Be With Proportional Lift, (Ansi / Csa)

    May 2015 Service Manual Electrical Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift, (ANSI / CSA) Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...
  • Page 184 Service Manual May 2015 Electrical Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift, (ANSI / CSA)

  • Page 185: Electrical Schematic, Gs-4069 Be With 2 Speed Lift, (As / Ce)

    May 2015 Service Manual Electrical Schematic, GS-4069 BE with 2 Speed Lift, (ANSI / CSA)
  • Page 186 Service Manual May 2015 Electrical Schematic, GS-4069 BE with 2 Speed Lift, (ANSI / CSA) GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 187: Electrical Schematic, Gs-4069 Be With Proportional Lift, (Ansi / Csa)

    May 2015 Service Manual Electrical Schematic, GS-4069 BE with Proportional Lift, (ANSI / CSA) Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...
  • Page 188 Service Manual May 2015 Electrical Schematic, GS-4069 BE with Proportional Lift, (ANSI / CSA)
  • Page 189 May 2015 Service Manual Electrical Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift, (AS / CE)

  • Page 190: Electrical Schematic, Gs-2669 Be And Gs-3369 Be With 2 Speed Lift, (As / Ce)

    Service Manual May 2015 Electrical Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift, (AS / CE) GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 191: Electrical Schematic, Gs-2669 Be And Gs-3369 Be With Proportional Lift, (As / Ce)

    May 2015 Service Manual Electrical Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift, (AS / CE) Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...
  • Page 192 Service Manual May 2015 Electrical Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift, (AS / CE)
  • Page 193 May 2015 Service Manual Electrical Schematic, GS-4069 BE with 2 Speed Lift, (AS / CE)

  • Page 194: Electrical Schematic, Gs-4069 Be With 2 Speed Lift, (As / Ce)

    Service Manual May 2015 Electrical Schematic, GS-4069 BE with 2 Speed Lift, (AS / CE) GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 195: Electrical Schematic, Gs-4069 Be With Proportional Lift, (As / Ce)

    May 2015 Service Manual Electrical Schematic, GS-4069 BE with Proportional Lift, (AS / CE) Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...
  • Page 196 Service Manual May 2015 Electrical Schematic, GS-4069 BE with Proportional Lift, (AS / CE)
  • Page 197 May 2015 Service Manual Hydraulic Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift...

  • Page 198: Hydraulic Schematic, Gs-2669 Be And Gs-3369 Be With 2 Speed Lift

    Service Manual May 2015 Hydraulic Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 199: Hydraulic Schematic, Gs-2669 Be And Gs-3369 Be With Proportional Lift

    May 2015 Service Manual Hydraulic Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...
  • Page 200 Service Manual May 2015 Hydraulic Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift...
  • Page 201 May 2015 Service Manual Hydraulic Schematic, GS-4069 BE with 2 Speed Lift...

  • Page 202: Hydraulic Schematic, Gs-4069 Be With 2 Speed Lift

    Service Manual May 2015 Hydraulic Schematic, GS-4069 BE with 2 Speed Lift GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106...

  • Page 203: Hydraulic Schematic, Gs-4069 Be With Proportional Lift

    May 2015 Service Manual Hydraulic Schematic, GS-4069 BE with Proportional Lift Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE...
  • Page 204 Service Manual May 2015 Hydraulic Schematic, GS-4069 BE with Proportional Lift GS-2669 BE • GS- 3369 BE • GS-4069 BE Part No. 1257106 Servic e M anual May 2015...

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