Terex Genie GS-2669 DC Service And Repair Manual
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Terex Genie GS-2669 DC Service And Repair Manual

Terex Genie GS-2669 DC Service And Repair Manual

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Service and Repair Manual
GS
-2669 DC
™
GS
-3369 DC
™
GS
-4069 DC
™
Serial Number Range
from GS69F-18000
from GS69M-101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Part No. 1306585GT
Rev A
May 2021

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Summary of Contents for Terex Genie GS-2669 DC

  • Page 1 Service and Repair Manual Serial Number Range -2669 DC ™ from GS69F-18000 This manual includes: from GS69M-101 Repair procedures -3369 DC ™ Fault Codes Electrical and -4069 DC ™ Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Introduction

    Copyright © 2020 by Terex Corporation 1306585GT Rev A, May 2021 Second Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GS” is a trademark of Terex South Dakota, Inc.

  • Page 3: Revision History

    May 2021 Service and Repair Manual Introduction Revision History Revision History Revision Date Section Procedure / Page / Description 5/2021 Initial Release Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual May 2021 Introduction Serial Number Legend 1 Model 4 Serial label, ((located inside cover)) 2 Facility code 5 Serial number, ((stamped on chassis)) 3 Sequence number ™ -2669 DC • GS ™ -3369 DC • GS ™...

  • Page 5: Safety Rules

    May 2021 Service and Repair Manual Safety Rules General Safety Rules Section 1 Safety Rules 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...
  • Page 6 Service and Repair Manual May 2021 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine Any person working on or around a machine must be aware of all known safety hazards. must be aware of all known safety hazards. Personal safety and the continued safe Personal safety and the continued safe operation of the machine should be your top...

  • Page 7: Table Of Contents

    May 2021 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History ..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
  • Page 8 May 2021 Table of Contents Section 3 Repair Procedures ..................... 10 Introduction ......................10 Platform Controls ....................12 1-1 Circuit Board ....................13 1-2 Joystick ......................14 1-3 Platfrom Controls Alarm ................. 15 1-4 Platfrom Emergency Stop Button ..............15 Platform Components ..................
  • Page 9 May 2021 Table of Contents Hydraulic Pump ....................46 5-1 Hydraulic Pump ....................46 How to Test the Hydraulic Pump ..............46 How to Remove the Hydraulic Pump .............. 46 How to Calibrate the Hydraulic Pump ............. 47 Manifolds ......................49 6-1 Function Manifold Components ..............
  • Page 10 May 2021 Table of Contents Non-steer Axle Components ................73 9-1 Drive Motors ....................73 9-2 Drive Hub ....................... 75 Outrigger Components ..................76 10-1 Outrigger Cylinder ..................76 10-2 Outrigger Calibration ..................77 Platform Overload Components ............... 79 How to Calibrate the Platform Overload System ..........79 11-2 Platform Overload Recovery ................
  • Page 11 May 2021 Table of Contents Section 4 Fault Codes ......................84 Introduction ......................84 GCON I/O Map ..................... 87 Control System Fault Codes ................89 Platform Overload Fault Codes ................. 94 Operation Indicator Codes (OIC) ................99 Diagnostic Trouble Codes (DTC) ................. 99 Troubleshooting "HXXX"...
  • Page 12 May 2021 Table of Contents Section 5 Schematics ....................... 115 Introduction ......................115 Electrical Schematic Abbreviations and Wire Color Legends ......116 Hydraulic Component Legend ................119 Electrical Symbols Legend ................. 120 Hydraulic Symbols Legend ................121 Limit Switch Legend ................... 122 Fuse, Ground and Platform Control Boxes ...........

  • Page 13: Specifications

    May 2021 Service and Repair Manual Specifications Performance Specifications Performance Specifications Section 2 Specifications Machine Specifications Machine Specifications Drive speed, maximum Fluid capacities Platform stowed 4.5 mph Hydraulic tank 16.5 gallons Forward direction 7.2 km/h (maximum fill capacity) 62.5 liters 40 ft / 6.1 sec 18 gallons Hydraulic system (including tank)

  • Page 14: Hydraulic Oil Specifications

    Service and Repair Manual May 2021 Specifications Hydraulic Oil Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
  • Page 15 May 2021 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C 15.0 cSt @ 104°F / 40°C 33.5...
  • Page 16 Service and Repair Manual May 2021 Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...

  • Page 17: Hydraulic Component Specifications

    May 2021 Service and Repair Manual Specifications Hydraulic Component Manifold Component Hydraulic Component Specifications Manifold Component Specifications Specifications Specifications Function Pump Plug torque Type gear pump SAE No. 2 36 in-lbs / 4 Nm Displacement 0.4 cu in SAE No. 4 10 ft-lbs / 13 Nm 6 cc SAE No.

  • Page 18: Machine Component Weights

    Service and Repair Manual May 2021 Specifications Machine Component Weights Battery Specifications Machine Component Weights Battery Specifications T105 936 lbs Platform assembly 425 kg Type 6v DC Link assembly (GS-4069) 3430 lbs Quantity 1556 kg Capacity 225 AH Link assembly (GS-3369) 2607 lbs Reserve capacity @ 25A rate 447 minutes...

  • Page 19: Hydraulic Hose And Fitting Torque Specifications

    May 2021 Service and Repair Manual Specifications Hydraulic Hose and Fitting Hydraulic Hose and Fitting Torque Specifications SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37°...

  • Page 20: Torque Procedure

    Service and Repair Manual May 2021 Specifications Torque Procedure 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 Replace the O-ring.
  • Page 21 May 2021 Service and Repair Manual 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 22: Repair Procedures

    Service and Repair Manual May 2021 Repair Procedures Machine Configuration: Section 3 Repair Procedures Introduction  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 Repair procedures shall be completed by a...
  • Page 23 May 2021 Service and Repair Manual 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 24: Platform Controls

    Service and Repair Manual May 2021 Platform Controls Platform controls Operational Indicator Codes Platform Controls (OIC) The platform controls are used to operate the machine from the platform. These codes are generated by the electrical system to indicate machine operating status. Activating a function button sends a signal to the During normal operation a code will appear in the Electronic Control Module (ECM).

  • Page 25: Circuit Board

    May 2021 Service and Repair Manual Platform Controls 1-1 Circuit Board 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 26: Joystick

    Service and Repair Manual May 2021 Platform Controls 1-2 Joystick Carefully disconnect the joystick wire harness from the platform controls circuit board. Joystick Electrocution/burn hazard. Contact with electrically charged How to Remove the Joystick circuits could result in death or serious injury.

  • Page 27: Platfrom Controls Alarm

    May 2021 Service and Repair Manual Platform Controls 1-3 Platfrom Controls Alarm 1-4 Platfrom Emergency Stop Button Platform Controls Alarm Platform Emergency Stop Button How to Remove the Platform How to Remove the Platform Controls Alarm Controls Emergency Stop Button Push in the red Emergency Stop button to the Push in the red Emergency Stop button to the off position at both the ground and platform...
  • Page 28 Service and Repair Manual May 2021 Platform Controls Carefully remove the Emergency Stop base from the Emergency Stop button. Carefully remove the retaining ring from the Emergency Stop button. Carefully remove the Emergency Stop button from the platform control box. ™...

  • Page 29: Platform Components

    May 2021 Service and Repair Manual Platform Components Platform Components 2-1 Platform 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.

  • Page 30: Platform Extension Deck

    Service and Repair Manual May 2021 Platform Components 2-2 Platform Extension Deck 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 31 May 2021 Service and Repair 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.

  • Page 32: Scissor Components

    Service and Repair Manual May 2021 Scissor Components 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 33: Scissor Assembly, Gs-2669 Dc

    May 2021 Service and Repair Manual Scissor Components 3-1 Scissor Assembly, GS-2669 DC Using a suitable supporting device, attach a strap to the rod end of the lift cylinder. Do not Scissor Assembly, GS-2669 DC apply pressure. Remove the lift cylinder rod end pivot pin How to Disassemble the Scissor retaining fasteners.
  • Page 34 Service and Repair Manual May 2021 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.
  • Page 35 May 2021 Service and Repair 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 36: Scissor Assembly, Gs-3369 Dc

    Service and Repair Manual May 2021 Scissor Components 3-2 Scissor Assembly, GS-3369 DC Using an overhead lifting device attach a 4 hook sling chain to the ends of the number Scissor Assembly, GS-3369 DC 4 inner arm. Make the chains tight but do not apply lifting pressure.
  • Page 37 May 2021 Service and Repair 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 38 Service and Repair Manual May 2021 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.
  • Page 39 May 2021 Service and Repair 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 40: Scissor Assembly, Gs-4069 Dc

    Service and Repair Manual May 2021 Scissor Components 3-3 Scissor Assembly, GS-4069 DC Using an overhead lifting device attach a 4 hook sling chain to the ends of the number Scissor Assembly, GS-4069 DC 4 inner arm. Make the chains tight but do not apply lifting pressure.
  • Page 41 May 2021 Service and Repair 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 42 Service and Repair Manual May 2021 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 43: Wear Pads

    May 2021 Service and Repair Manual Scissor Components 3-4 Wear Pads 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...
  • Page 44 Service and Repair Manual May 2021 Scissor Components Remove the retaining fasteners from the Using a hard rubber mallet, secure the upper slider 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...

  • Page 45: Lift Cylinders

    May 2021 Service and Repair Manual Scissor Components 3-5 Lift Cylinders 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 46: Height Angle Sensor

    Service and Repair Manual May 2021 Scissor Components Disassemble the scissor assembly. Refer to 3-6 Height Angle Sensor Repair Procedure, How to Disassemble the Height Angle Sensor Scissor Assembly. How to Replace the Height Angle Sensor How to Replace the Height Angle Sensor Note: If the angle sensor is replaced, both the sensor and magnet must be replaced as a set.
  • Page 47 May 2021 Service and Repair Manual Scissor Components Remove the retaining fasteners securing the angle sensor mount to the sensor housing. Remove the sensor assembly and set aside. 1 sensor housing 2 sensor magnet 3 angle sensor 4 angle sensor mount Remove and replace the sensor magnet.

  • Page 48: Ground Controls

    Service and Repair Manual May 2021 Ground Controls 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 49: Software Revision Level

    May 2021 Service and Repair Manual Ground Controls 4-1 Software Revision Level 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...

  • Page 50: Machine Setup

    Service and Repair Manual May 2021 Ground Controls 4-2 Machine Setup 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.

  • Page 51: Auxiliary Platform Lowering

    May 2021 Service and Repair Manual Ground Controls 4-3 Auxiliary Platform Lowering 4-4 Level Sensor - Models without Outriggers 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 programmed to deactivate the lift and drive...
  • Page 52 Service and Repair Manual May 2021 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 53 May 2021 Service and Repair 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 the ground controls side of the machine. 25 cm thick steel block under both wheels at the ground controls side of the machine.

  • Page 54: Level Sensor - Models With Outriggers

    Service and Repair Manual May 2021 Ground Controls 4-5 Level Sensor - Models with Outriggers 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 55 May 2021 Service and Repair 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 tighten the level sensor retaining fasteners.

  • Page 56: Service Override Mode

    Service and Repair Manual May 2021 Ground Controls 4-6 Service Override Mode 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 57 May 2021 Service and Repair 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 58: Hydraulic Pump

    Service and Repair Manual May 2021 Hydraulic Pump How to Remove the Hydraulic Hydraulic Pump How to Remove the Hydraulic Pump 5-1 Hydraulic Pump Pump Hydraulic Pump Tag, disconnect and plug the hydraulic hoses The hydraulic pump is a single section, gear-type on the pump.

  • Page 59: How To Calibrate The Hydraulic Pump

    May 2021 Service and Repair Manual Hydraulic Pump How to Calibrate the Hydraulic How to Calibrate the Hydraulic Pump 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 60 Service and Repair Manual May 2021 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 61: Manifolds

    May 2021 Service and Repair Manual Manifolds Manifolds 6-1 Function Manifold Components Function Manifold Components The function manifold is located inside the hydraulic compartment. Index Schematic Description Function Torque Item Relief valve Oscillate relief 20 ft-lbs / 27 Nm Accumulator Oscillate circuit 11 ft-lbs / 15 Nm Relief valve...
  • Page 62 Service and Repair Manual May 2021 Manifolds ™ -2669 DC • GS ™ -3369 DC • GS ™ -4069 DC Part No. 1306585GT...

  • Page 63: Valve Adjustments - Function Manifold

    May 2021 Service and Repair Manual Manifolds Remove the pressure gauge. 6-2 Valve Adjustments - Function Manifold Valve Adjustments - Function Manifold How to Check the System Proportional Relief Valve How to Check the System Proportional Relief Valve Note: Perform this procedure with the machine in the stowed position.

  • Page 64: How To Adjust The Oscillate Relief Valve

    Service and Repair Manual May 2021 Manifolds 11 Remove the pressure gauge. How to Adjust the Oscillate Relief How to Adjust the Oscillate Relief Valve 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 65: How To Adjust The Steer Relief Valve

    May 2021 Service and Repair Manual Manifolds 10 Remove the pressure gauge. How to Adjust the Steer Relief How to Adjust the Steer Relief Valve 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 66: How To Adjust The Platform Up Relief Valve

    Service and Repair Manual May 2021 Manifolds Press and hold the ground control scroll up How to Adjust the Platform Up How to Adjust the Platform Up Relief Valve and scroll down buttons. Relief Valve Note: Verify the hydraulic oil level is within the top 2 inches / 5 cm of the sight gauge.
  • Page 67 May 2021 Service and Repair Manual Manifolds 10 Press the Scroll Down button to scroll to At the ground controls, use the Scroll Down Down Delay. button to scroll to SELECT OPTION. Result: The ground controls LCD display will Result: The ground controls LCD display will show the following: show the following: 11 Press the enter button.
  • Page 68 Service and Repair Manual May 2021 Manifolds 16 Lower the platform onto the safety arm. 24 Hold the lift relief valve (item 1) with a wrench and remove the cap. 17 Push in the red Emergency Stop button to the off position.
  • Page 69 May 2021 Service and Repair Manual Manifolds 39 Pull out the red Emergency Stop button to the 44 Press the enter button. on position at the ground controls. Result: The ground controls LCD display will Result: The ground controls LCD display will show the following: show the following: Note: After 1 second the display will return to...
  • Page 70 Service and Repair Manual May 2021 Manifolds 47 Press the enter button. Result: The ground controls LCD display will show the following: Note: After 1 second the display will return to SELECT OPTION, DOWN DELAY. 48 Push in the red Emergency Stop button to the off position.

  • Page 71: Outrigger Manifold Components

    May 2021 Service and Repair Manual Manifolds 6-3 Outrigger Manifold Components Outrigger Manifold Components The outrigger manifold is located inside the hydraulic compartment. Index Schematic Description Function Torque Item Solenoid valve, 3 position 4 way Outriggers extend / retract 40 ft-lbs / 54 Nm Part No.

  • Page 72: Valve Coils

    Service and Repair Manual May 2021 Manifolds Valve Coil Resistance 6-4 Valve Coils 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 73 May 2021 Service and Repair Manual Manifolds 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. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.

  • Page 74: Hydraulic Tank

    Service and Repair Manual May 2021 Hydraulic Tank Hydraulic Tank 7-1 Hydraulic Tank 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.

  • Page 75: Steer Axle Components

    May 2021 Service and Repair Manual Steer Axle Components Steer Axle Components 8-1 Yoke Assembly Left side yoke: Yoke Assembly Remove the retaining fasteners from the tie rod pivot pin. How to Remove the Yoke Assembly Chock both sides of the wheels at the non- steer end of the machine.
  • Page 76 Service and Repair Manual May 2021 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...

  • Page 77: Steer Cylinder

    May 2021 Service and Repair Manual Steer Axle Components 8-2 Steer Cylinder 8-3 Tie Rod 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 78: Oscillate Cylinder

    Service and Repair Manual May 2021 Steer Axle Components 8-4 Oscillate Cylinder 8-5 Oscillate Hoses 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 79 May 2021 Service and Repair Manual Steer Axle Components Disconnect the connector with the green/black Turn the key switch to platform control and wire from the oscillate right coil (item 2) and pull out the red Emergency Stop button to the swap it with the connector with the blue wire on position at both the ground and platform from the steer right coil (item 3).

  • Page 80: Steer Angle Sensor

    Service and Repair Manual May 2021 Steer Axle Components 8-6 Steer Angle Sensor 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 81 May 2021 Service and Repair Manual Steer Axle Components 11 Set the spacer plate aside. 16 Rotate the tie rod pivot pin until it is approximately 90° from the mounting tab on the tie rod. 17 Install the steer sensor actuator onto the tie 1 steer sensor cover rod pivot pin.
  • Page 82 Service and Repair Manual May 2021 Steer Axle Components How to Calibrate the Steer Angle Release the Scroll Up and Scroll Down Sensor buttons after the ground controller powers up. At the ground controls, use the Scroll Down Turn the key switch to the ground controls button to scroll to SELECT OPTION.
  • Page 83 May 2021 Service and Repair Manual Steer Axle Components 10 Press the enter button. 13 Press the enter button. Result: The ground controls LCD display will Result: The ground controls LCD display will show the following: show the following: Note: The platform controls do not have to be connected at the chassis ground controls.
  • Page 84 Service and Repair Manual May 2021 Steer Axle Components 16 Use the platform drive controller steer function to turn the steer tires fully to the left. 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 displayed, repeat this procedure.

  • Page 85: Non-Steer Axle Components

    May 2021 Service and Repair Manual Non-steer Axle Components Non-steer Axle Components 9-1 Drive Motors Remove the wheel lug bolts. Remove the tire and wheel assembly. Drive Motors Remove the axle cover. How to Remove a Drive Motor The drive motors are AC powered and are a brushless design requiring very little maintenance.
  • Page 86 Service and Repair Manual May 2021 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 87: Drive Hub

    May 2021 Service and Repair Manual Non-steer Axle Components 9-2 Drive Hub 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 88: Outrigger Components

    Service and Repair Manual May 2021 Outrigger Components Outrigger Components 10-1 10-1 Outrigger Cylinder 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.

  • Page 89: Outrigger Calibration

    May 2021 Service and Repair Manual Outrigger Components 10-2 10-2 Outrigger Calibration 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 90 Service and Repair Manual May 2021 Outrigger Components Use the Scroll Up or Scroll Down buttons to scroll to Outriggers. Press the Enter button to select Outriggers. 10 Use the Scroll Up or Scroll Down buttons to scroll to Calibrate Outriggers. 11 Press the Enter button to select Calibrate Outriggers.

  • Page 91: Platform Overload Components

    May 2021 Service and Repair Manual Platform Overload Components Result: The red LED is on and the LCD Platform Overload Components How to Calibrate the Platform How to Calibrate the Platform Overload System screen displays LOAD. Overload System Machines with platform overload systems, proper calibration is essential to safe machine operation.
  • Page 92 Service and Repair Manual May 2021 Platform Overload Components Confirm Calibration: Activate and hold the calibration toggle switch in the up position for 4 seconds to enter full Add additional weight to the platform. load calibration mode. Model Additional weight Result: The LCD screen first displays DOWN GS-2669 300 lbs...

  • Page 93: Platform Overload Recovery

    May 2021 Service and Repair Manual Platform Overload Components 11-2 11-2 Platform Overload Recovery Pull out the red Emergency Stop button at the ground controls. Platform Overload Recovery Message Result: The ground control LCD display will 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 94 Service and Repair Manual May 2021 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.

  • Page 95: Down Limit Height

    May 2021 Service and Repair Manual Platform Overload Components 11-3 11-3 Down Limit Height Connect the Tech Pro Link to the machine. Down Limit Height Turn the key switch to ground control and pull out the red Emergency Stop button to the on How to Calibrate the Down Limit Height position at both ground and platform controls.

  • Page 96: Fault Codes

    Service and Repair Manual May 2021 Fault Codes Section 4 Fault Codes Before Troubleshooting: Introduction 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 ...

  • Page 97: About This Section

    May 2021 Service and Repair Manual 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 98 Service and Repair Manual May 2021 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).

  • Page 99: Gcon I/O Map

    May 2021 Service and Repair Manual Fault Codes GCON I/O Map GCON I/O MAP Ground Controls Circuit Function I/O Type Wire Color 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...
  • Page 100 Service and Repair Manual May 2021 Fault Codes GCON I/O MAP Ground Controls Circuit Function I/O Type Wire Color Pin Number 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...

  • Page 101: Control System Fault Codes

    May 2021 Service and Repair Manual Control System Fault Codes Control System Fault Codes LED Diagnostic Readout The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions. The dot to the right of the numbers remain on when a fault code is displayed.
  • Page 102 Service and Repair Manual May 2021 Fault Codes System Ready LED Condition Result Solution INTERNAL ECU Internal ECM error. System shutdown. Replace ECM. FAULT PLATFORM ECU Platform/ECM System shutdown. Troubleshoot control cable OR FAULT communication error. troubleshoot platform controls. CHASSIS START Engine start button fault at Engine will not Replace ECM.
  • Page 103 May 2021 Service and Repair Manual Fault Codes System Ready LED Condition Result Solution PLATFORM Engine start button fault at Engine will not start. Troubleshoot button OR START SW platform controls. replace printed circuit board FAULT at platform controls. LEFT FRONT Left front outrigger enable Outriggers disabled.
  • Page 104 Service and Repair Manual May 2021 Fault Codes System Ready LED Condition Result Solution DRIVE COIL 2 Drive coil 2 (Y1A) fault. High speed drive Troubleshoot coil OR wiring. FAULT function will not operate. DRIVE COIL 3 Drive coil 3 (Y1B) fault. High speed drive Troubleshoot coil OR wiring.
  • Page 105 May 2021 Service and Repair Manual Fault Codes System Ready LED Condition Result Solution HIGH COOLANT High coolant temperature. High engine Gasoline/LPG models: Check TEMPERATURE temperature OR the engine radiator coolant defective engine level OR check the wiring from coolant or oil the water temperature switch temperature switch.

  • Page 106: Platform Overload Fault Codes

    Service and Repair Manual May 2021 Platform Overload Fault Codes Platform Overload Display Platform Overload Fault Codes 1 LCD screen 2 red LED The diagnostic readout displays numerical codes that provide information about height sensor, pressure sensor and platform overload malfunctions. The codes listed in the Fault Code Chart can aid in troubleshooting the machine by pinpointing the area or component affected.
  • Page 107 May 2021 Service and Repair Manual Fault Codes Error Source Error Type Condition Solution Name ID Name Height sensor 12 Value too high Output higher than • Check wiring normal. • Check 5V supply voltage • Shorted too high • Replace sensor 14 Cross check fault Height channels not •...
  • Page 108 Service and Repair Manual May 2021 Fault Codes Error Source Error Type Condition Solution Name ID Name Height sensor 12 Value too high Output higher than • Check wiring normal. (Safety) • Check 5V supply voltage • Shorted too high •...
  • Page 109 May 2021 Service and Repair Manual Fault Codes Error Source Error Type Condition Solution Name ID Name Pressure sensor 12 Value too high Output higher than • Check wiring normal. • Check 5V supply voltage • Shorted too high • Replace sensor 14 Cross check fault Pressure channels not •...
  • Page 110 Service and Repair Manual May 2021 Fault Codes Error Source Error Type Condition Solution Name ID Name SCON - Safety 29 Software Primary and secondary • Update software controller version processors software do not • Replace SCON mismatch match. Platform Overload 23 Too high Platform overloaded.

  • Page 111: Operation Indicator Codes (Oic)

    May 2021 Service and Repair Manual Fault Codes Operation Indicator Codes (OIC) Diagnostic Trouble Codes (DTC) 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 112: Troubleshooting "Hxxx" And "Pxxx" Faults

    Service and Repair Manual May 2021 Fault Codes Troubleshooting "HXXX" and "PXXX" Faults 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 113: Fault Inspection Procedure

    May 2021 Service and Repair Manual Fault Codes Fault Inspection Procedure 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.
  • Page 114 Service and Repair Manual May 2021 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 C1-7 (ground) and the GCON pin associated with the fault code.

  • Page 115: Type "Hxxx" Faults

    May 2021 Service and Repair Manual Fault Codes Type "HXXX" Faults 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 116 Service and Repair Manual May 2021 Fault Codes Type "HXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD H066:COILFAULT Short circuit of the right rear outrigger • Short circuit in right rear outrigger coil harness. All functions inhibited H066 RR RIGGER:Bat+ coil to battery positive.
  • Page 117 May 2021 Service and Repair Manual Fault Codes Type "HXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD H089:COILFAULT Open circuit of the oscillate left • Open circuit in oscillate left harness. All functions inhibited H089 OSC LEFT:Open circuit.

  • Page 118: Type "Pxxx" Faults

    Service and Repair Manual May 2021 Fault Codes Type "PXXX" Faults 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.
  • Page 119 May 2021 Service and Repair Manual Fault Codes Type "PXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD P032:COILFAULT Short or open circuit of the left rear • Short or open circuit in left rear brake harness. P032 All functions inhibited.

  • Page 120: Type "Uxxx" Faults

    Service and Repair Manual May 2021 Fault Codes Type "UXXX" Faults 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 121 May 2021 Service and Repair Manual Fault Codes Type "UXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD U033:JSTICKFAULT PCON drive joystick signal is • PCON drive joystick is not in neutral position range at All drive and steer U033 OUT OF CAL RANGE outside acceptable calibration.

  • Page 122: Type "Fxxx" Faults

    Service and Repair Manual May 2021 Fault Codes Type "FXXX" Faults 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 123 May 2021 Service and Repair Manual Fault Codes Type "FXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD F049:SENSORFAULT Short circuit of the pump speed • Short circuit of the pump speed sensor. F049 All functions operate. PUMP SPEED:Bat+ sensor to battery positive.
  • Page 124 Service and Repair Manual May 2021 Fault Codes Type "FXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD F064:SWITCHFAULT Left axle safety limit switch state not • Short or open circuit of the left axle safety and/or All functions inhibited F064 LEFT AXLE:MISM...

  • Page 125: Type "Cxxx" Faults

    May 2021 Service and Repair Manual Fault Codes Type "CXXX" Faults 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 •...
  • Page 126 Service and Repair Manual May 2021 Fault Codes Type "CXXX" Faults, continued Message on Description Possible Causes Failure Mode Number GCON LCD C034:DCON RR ECM Valve driver failure of the right rear C034 • Right rear DCON ECM. Drive functions inhibited. FAULT TYPE 03 drive controller.

  • Page 127: Schematics

    May 2021 Service and Repair Manual Schematics About This Section Section 5 Schematics Introduction 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.

  • Page 128: Electrical Schematic Abbreviations And Wire Color Legends

    Service and Repair Manual May 2021 Electrical Schematic Abbreviations and Wire Color Legends Electrical Schematic Abbreviations and Wire Color Legends Electrical Component Legend Option Gauge Item Description Diagnostic display Battery Horn or alarm 48V DC Battery pack Horn Button Multi-function alarm (ground) High speed function enable (platform) Alarm (platform) Platform up / Outrigger retract (platform)
  • Page 129 May 2021 Service and Repair Manual Electrical Schematic Abbreviations and Wire Color Legends Valve coil Electrical Component Legend, continued Steer right / CW Item Description Steer left / CCW Resistor Drive reverse 2k ohm Platform down 51 ohm Platform down (GS-4069 models) 51 ohm Platform up 180 ohm...
  • Page 130 Service and Repair Manual May 2021 Electrical Schematic Abbreviations and Wire Color Legends Wire Color Legend Color Description Blue Black Brown Green Orange Purple White Yellow BL/RD Blue/Red BL/WH Blue/White BK/RD Black/Red OR/WH Orange/White RD/BK Red/Black RD/WH Red/White WH/BL White Blue WH/BK White/Black WH/RD...

  • Page 131: Hydraulic Component Legend

    May 2021 Service and Repair Manual Hydraulic Component Legend Hydraulic Component Legend Item Function Item Function 3 position, 4 way directional valve - Relief valve - main system outrigger 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 132: Electrical Symbols Legend

    Service and Repair Manual May 2021 Electrical Symbols Legend 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...

  • Page 133: Hydraulic Symbols Legend

    May 2021 Service and Repair Manual Hydraulic Symbols Legend Hydraulic Symbols Legend Orifice with size Check valve Cylinder, double acting Accumulator Pump, prime mover Pump, fixed displacement Priority flow regulator Needle valve (engine or motor) Solenoid operated Solenoid operated Solenoid operated Solenoid operated 3 position 4 way directional 3 position 5 way...

  • Page 134: Limit Switch Legend

    Service and Repair Manual May 2021 Limit Switch Legend Limit Switch Legend 1 left rear outrigger limit switch, LS14 5 right front outrigger limit switch, LS13 left front outrigger limit switch, LS12 (not 2 left axle oscillate limit switches, LSA10S shown) and LSA10SS 3 right rear outrigger limit switch, LS15...

  • Page 135: Fuse, Ground And Platform Control Boxes

    May 2021 Service and Repair Manual use, Ground and Platform Control Boxes Fuse Box Layout, All Models...

  • Page 136: Fuse Box Layout, All Models

    Service and Repair Manual May 2021 Fuse Box Layout, All Models Fuse Box Layout, All Models ™ -2669 DC • GS ™ -3369 DC • GS ™ -4069 DC Part No. 1306585GT...

  • Page 137: Ground Control Box Layout

    May 2021 Service and Repair Manual Ground Control Box Layout Ground Control Box Layout TS51 TS10 TS51 TS10 TERMINAL BASE (TB) CR61 B 108 B 109 B 110 B 111 CR60 B 34 C 78 B 33 B 35 C 77 (FRONT) MODELS WITHOUT MODELS WITH...
  • Page 138 Service and Repair Manual May 2021 Ground Control Box Layout...

  • Page 139: Platform Control Box Layout

    May 2021 Service and Repair Manual Platform Control Box Layout Platform Control Box Layout Part No. 1306585GT ™ -2669 DC • GS ™ -3369 DC • GS ™ -4069 DC...
  • Page 140 Service and Repair Manual May 2021 Platform Control Box Layout...

  • Page 141: Electrical Schematics

    May 2021 Service and Repair Manual Electrical Schematics Electrical Schematic...

  • Page 142: Electrical Schematic

    Service and Repair Manual May 2021 Electrical Schematic Electrical Schematic JC3 DRIVE/STEER JOYSTICK PCON V+ GROUND P181BAT OR E-STOP ALARM P182BAT RD CAN+ GROUND C174KS WH CAN- R179PWR GR ESTOP+ PCON V- ESTOP - GND BR 1 2 3 4 5 SMARTLINK C134PWR RD C27-4...
  • Page 143 May 2021 Service and Repair Manual Electrical Schematic GTPL1 P182PWR A LOAD SENSE GND B D82CAN+ D D81CAN- E SC050 C22PCN D82CAN+ YL D82CAN+ CAN+ 0 D81CAN- D81CAN- CAN- 0 P182PWR C145CAL RD/WH CALIBRATE C22PCN P109PWR RD C40LS P110RET SNSR GROUND C134PWR C134PWR RD 11 C134PWR MONITOR...
  • Page 144 Service and Repair Manual May 2021 Electrical Schematic...

  • Page 145: Hydraulic Schematics

    May 2021 Service and Repair Manual Hydraulic Schematics Hydraulic Schematic...

  • Page 146: Hydraulic Schematic

    Service and Repair Manual May 2021 Hydraulic Schematic Hydraulic Schematic HS0256K GS™-2669 DC • GS™-3369 DC • GS™-4069 DC Part No. 1306585GT Service and Repair Manual May 2021 ™ -2669 DC • GS ™ -3369 DC • GS ™ -4069 DC Part No.

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