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Service and Repair Manual
GS-2669 DC
GS-3369 DC
GS-4069 DC
Serial Number Range
from GS6912-1300
from GS6916F-7897to
GS6916F-10499
From GS69F-10500
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. 1272220GT
Rev A2
November 2016
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Chapters
Table of Contents
Troubleshooting
Related Manuals for Genie GS-4069 DC
Summarization of Contents
Introduction and General Information
Introduction to Manual
Overview of the manual, including important information and contact details.
Revision History
Details revisions made to the manual, including dates, sections, and descriptions.
Serial Number Legend
Explains the components of serial numbers for machine identification.
Safety Rules
Critical Safety Warnings
Highlights danger, and conditions required before performing maintenance.
Personal and Workplace Safety
Emphasizes hazard awareness, safety practices for operations and work areas.
Specifications
Machine Specifications
Details fluid capacities, tire specifications, and weight.
Performance Specifications
Lists drive speeds, braking distance, gradeability, and function speeds.
Hydraulic Oil Specifications
Specifies requirements for hydraulic oils, cleanliness, and fluid properties.
Hydraulic Component Specifications
Details pump, manifold, and battery specifications.
Torque Specifications
Provides torque values for hydraulic hose and fitting connections.
Repair Procedures
General Repair Guidelines
Covers safety, preparation, and general procedure guidelines.
Symbols Legend
Explains symbols used to indicate hazards and results in procedures.
Platform Controls
Platform Control System
Describes the function and components of platform controls.
Operational Indicator Codes (OIC)
Explains codes displayed on controls indicating machine status.
Platform Components
Platform Removal
Procedure for removing the platform from the machine.
Platform Extension Deck Removal
Instructions for removing the platform extension deck.
Scissor Components
Scissor Assembly Overview
Diagram illustrating the numbered components of the scissor assembly.
Scissor Assembly Procedures
Details disassembly procedures for GS-2669, GS-3369, and GS-4069 DC models.
Wear Pads Replacement
Procedure for replacing scissor arm wear pads.
Lift Cylinders Removal
Procedure for removing lift cylinders for GS-2669, GS-3369, and GS-4069 models.
Ground Controls
Ground Control System Overview
Describes the function and components of ground controls.
Machine Setup and Calibration
Procedures for software revision, machine setup, and sensor calibration.
Service Override Mode
Explains the purpose and use of Service Override mode for repairs.
Hydraulic Pump
Pump Testing and Removal
Covers testing, removal, and replacement of the hydraulic pump.
Hydraulic Pump Calibration
Procedure for calibrating the hydraulic pump's efficiency settings.
Manifolds
Function Manifold Components
Lists and describes components within the function manifold.
Valve Adjustments
Procedures for adjusting system, oscillate, steer, and platform relief valves.
Outrigger Manifold Components
Details the solenoid valve for outrigger extension/retraction.
Valve Coil Testing
Explains testing procedures and specifications for solenoid valve coils and diodes.
Hydraulic Tank
Hydraulic Tank Functions
Describes the primary functions of the hydraulic tank.
Hydraulic Tank Removal
Step-by-step instructions for removing the hydraulic tank.
Steer Axle Components
Yoke Assembly Removal
Procedure for removing the yoke assembly from the steer end.
Drive Motor Removal
Instructions for removing the drive motor from the yoke.
Steer Cylinder and Tie Rod Removal
Procedures for removing the steer cylinder and tie rod.
Oscillate Cylinder and Hoses
Procedures for removing oscillate cylinder and testing hoses.
Steering System Checks
Procedures to verify correct steering function and axle oscillate.
Steer Angle Sensor Calibration
Explains sensor function and procedure for calibrating the steer angle sensor.
Non-steer Axle Components
Drive Motors
Describes AC powered, brushless drive motors and their sensors.
Drive Motor Removal
Instructions for removing the drive motor from the axle assembly.
Drive Hub Removal
Procedure for removing the drive hub from the axle assembly.
Outrigger Components
Outrigger Cylinder Removal
Procedure for removing an outrigger cylinder, if equipped.
Outrigger Calibration
Procedure for calibrating the outrigger level sensor for machine leveling.
Platform Overload Components
Platform Overload System
Explains the importance of proper calibration for safe operation.
System Calibration Procedures
Procedures to calibrate the platform overload system and height limit switch.
Platform Overload Troubleshooting
Troubleshooting common issues with the platform overload system.
Platform Overload Recovery Message
Explains and clears the OL: PLATFORM OVERLOADED message.
Fault Codes
Introduction and Definitions
Overview of fault codes, DTC types, and diagnostic system.
Diagnostic Readout and Connectors
Explains diagnostic readout codes and GCON ECM connector layouts.
GCON I/O Map
Pin assignments, circuit functions, I/O type, and wire colors for Ground Controls.
Fault Code Categories
Details HXXX, PXXX, UXXX, FXXX, and CXXX fault code types.
Troubleshooting and Inspection
Guides for troubleshooting specific faults and inspecting circuits.
Schematics
Schematic Introduction
Overview of electrical and hydraulic schematics.
Schematic Legends and Abbreviations
Defines symbols, legends, and wire color codes for schematics.
Component Layout Diagrams
Diagrams showing fuse, ground, and platform control box layouts.
Electrical Schematics
Wiring diagrams for various models and serial number ranges.
Hydraulic Schematics
Hydraulic system diagrams for various models and serial number ranges.
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