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Service Manual

1. P1 C278 c1 12 15A ECON PCON V JC3 DRIVEISTEER JOYSTICK__ GROUND 01 lt P2 C271 011 1 PAPAT OR CB 7A ee ESTOP E STOP co RENS A E ALARM 02 lt RD Ha PCON P182BAT RD Zei t e CAN GROUNDGSZ BK ALARM T ESTOP 3 CAN ak E SEE EsTorslos wi g 1 C9 Gye PCON V VaOASEEZISYS ESTOP 05 lt WH ICO 2260511322828 tss gt a 254552 x bh Se eus enm C134PWR RD m oa v UY Y v U2 PCON gt l aware Y x d BY a A af e SMARTLINK 9 5 DI 023 Kn C123 P134PWR RD E S9 C41RPM GR E eee 1 C41RPM OREK E Mei F9 PIS4PWA RD n C134PWR RD 2 1 PHORET BK E ET PIORET BK PSS a EER E y A S SE o C134PWR RD LSXiOBS UPLS
2. P1 027 3 on 15A ECON POON V JC3 DRIVEISTEER JOYSTICK grounna ES C274 Ctt pd Sei 7A jd ESTOP Ser COE ARAB BE B ALARM 02 lt RD He Econ 1 P182BAT RD dor re CANE GROUND 03 lt BK el ALARM D ESTOP CAN BSS ERE EB SHS ESTOPA wn eis Co yy PCONV 2003463288 ESTOP 05 lt WH o ig bp pr 256 Di o6 627 5 C1 11 EEAORSE U2 PCON 5 sov 2E KI oe Cay VV YY y SMARTLINK ZE d Kl p 1 2 3 4 56 m Ges oan ko dj P134PWR RD Cas B cainPM GR E 1 CATRPM OR BK Es Ve Eege AD A C134PWR AD e e E 1 PT10RET BK a e PtHORET BK PS5 TT j 5 526 e C134PWR RD LSAT0SS UPLS aa ay BY NC ACCUM a UN 2 E E E k X E El El SPEED LEFT AXLE JNO 1 lora PRESS L e BK BK BK c SENSOR Ce osol 8 1 SES SWITCH DOWN L S pu als WH BL ca GECKEGE SWIA4 822018 C394 CIBANOMC y Er 2223 NO
3. C273 011 12 re Ki e R EON PCON V JC3DAIVESTEERJOYSTICK GROUND Gic 8 oer ena ca 7A 7 ESTOP Estop c RES E B aanwox nb He PCON P182BAT RD ce pe CANS GROUND OSC BK L ALARM ESTOP Ee ESAN Ss SBS HIS Eroro w 1 9 1 iad lt wl od vv E PCON V EREE EE 2 GEE 2 C27 5 CHA C122 252552 x 300 T ZA 46 U2 PCON q g iid RD lt TI SMARTUNK mic Es pilas lt a G23 d 2K a P134PWR RD C38 8 S caiRPM GR e cies C41RPM ORBK a H T P134PWR RD AK C134PWR RD gt U S 1 P110RET BK Ze PTIORET BK PS5 r 5 En Y GHAPWRRD 088 iy 27 a7 47 By e neo ACCUM al E E S E SR SENSOR LEFT AXLE A PRESS Les ee 2 12 c G C40 EE y SWITCH pown ES I4 3 222528 DIAS sees O84 ctea nome A m E2228 M S7 DIGITAL lamen 88 248 E marc ewm 057 UE NI STEEP Bis we xt EII THERM GND cu L AXLE OSC LS A6_ lt a C184 KOR 7 E SWITCH HABRe O ALARM HORN IHG i y 5 C26T5SR WH RD gt D3 THERM SENSOR Es A R AXLE OSC LS AS Z S228L8 YL PLAT E Tal EE H BK RIGHT lt ir c 4 DT858EN WH D1 ENCODER A uw 8 LS6B amp E 4 ae 6
4. Pi Gars eua P181BAT OR Ka T e GCON noe a VC we GE E GROUND aic pa C274 ci CB7 7A EsTOP E STOP ces mass se 2 ALARM O02 RD PCON P182BAT RD Sei pese CAN GROUND 03BK _ ALARM SR ESTOP CAN SNS SEES estor UEW 5 co yy PCONV ELITE 009 ESTOP 054 WH 2925552298 C124 We Uke OD 23885 E P538 ES 627 5 Ci1 11 j SZ See z gt a DI o7 C134PWR RD e lt lt cau V y l0 U2 PCON gt fide 2 Ri ELE SMARTLINK 8 ES mio Tm C28 cre za P134PWR RD H 638 Sp C4IRPMGR E C41RPM OR BK a 9 P134PWA RD A s A C134PWR RD E 16 PTIORET BK A PHIORET BK pss T E Y 5 326 DD Luss T 2 3f 4 9 nep ACCUM 8 gt lt TERT Ee LEFT ite Tm CS iS iN pue ce ce C334 Ca NO HG 5332 Y DOWNES P E 3 e FETE D sons Gi CUBANOS y Teg ke1 FEER e yomo Ba NE i 6 gt ce Su E DIAZ IE NC A KEY A TE T E ns H2 Voie SENSOR Dl ap f l J GND BR 308 THERM GND ge 2 L AXLE OSC LS AE lt 4 case 0184 HOS 7 T SWITCH 38385 O ALARM HORN o s l w 5 gt gt C26TSR WH RD 2D3 THERM SENSOR EE 3 PL AXLE OSG LS A5 22315 YL A E PLAT z Tal be Le EK RIGHT i fr 4 D185SEN WH
5. January 2015 167 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 RESERVOIR e 3 z EE A E 1 H i i 1 I I H kE i I i i p 4 2 3 1 1 E I f o m 1 gt I a H ae H i o 2 m gt 2 zi i MN ae Es a 1 Iri 1 Ma W A e I E ry Pra bg RU ET EA e Tha E E B8 r TI 3 d it e y i VS I mE a zi gt 1 1 E Es ER 9 E 3 sa X D 2 Ee AREN dr dom i NS 1 I UI I aM i e l Gel f 2i Ke d VIR e r l i 9 l i i Lu DI rat ei a NOE EC SE r 3 SR EEUE Ee E l E 6 LES e WOH Se DI 1 E Vr ees a i LH 3 1 Bop eee i ge ic i e a 2 gt rl a 148 pe 9 i set 11 SEV x eae MEE z H ee o _ lt e o e EL A q 9 S Ey LR IE al l z g ag A zi LE jigs Vo d i IERE FERA EE zi u S Nr IN 9 El oq S SA Q Neary N EN b 1 LP P i l 8 2 z T Le x CHE gg LEE 2 o zzi 1 j
6. a 3 z p a E PESA ees K 1 I I H I t Po Ee a 8 ad I m A i ul 1 1 1 I a E e i a Z i i l i ul c9 d 6 A Ua E i Pr i je ip opeeeeem Nee I E IO 1E I 1 BERE Er 1 Ed Lg 5 I LI 23 d E e O E E on 4 l i ul ER Le R A IE L E P gies Ex xe ioc o i E i E EK of 1 1 T Ia N I x E I a Su X ra rd DE El BEEN 1 fase Seo i IN UT ERN iu 3 d 1 l aN od Y I RE SE N AF I B i o g er P o N id Boe S ll ul t 5 _ API e WO e KL e H 1 E amp IL HOI A MEN 1 a Ee EA L oi _ ma r i 3 F Q PES Tl E B Bo gt Ka r1 g Sa 1d8 ta D an Le Es AN Le LS A lee Z e e He je m le toe D a 3 l a5 S p a No E Se as S ui X 1 ZS al o2 DY o z 3 i 8 fc IN 1 iL od aa ON lia IBAN de 2 l Ba 5 a I FS P 1 1 s D x gt E 2 33 i ee dr e 3 MEE gt zz n 1 o TERS 1 1 zje TT H I a Za gt cd Bs S B gis 25 x e usse i Lesch i c5 gel 8 m 2 1 apo A A y a o BE 3 8 a AE i zx o 8 o2 g Se e bin 3 C ag T I lt E 9 a o u OST Sate Sanaa ee pasa QU I uf y gt 1 l s u 260 im e e i 4i ed H gt mi E 1 x 2 A E S Ya zi lt pe ke ET For E WN ah LE i IN i me E y bs F r e Tess a
7. 1 function manifold Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 99 Service Manual January 2015 Steer Axle Components 2 Disconnect the connector with the green black 4 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 controls E 5 Slowly drive the machine in a safe direction and activate steer right Result The right oscillate cylinder will extend and the left oscillate cylinder will retract 6 Slowly drive the machine in a safe direction and activate steer left Result The left oscillate cylinder will extend and the right oscillate cylinder will retract 7 Turnthe key switch to the off position 8 Swap the connectors back to the correct coils using steps 2 an 3 as a reference Continue to Check the Steering Check the Steering 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Activate steer right and verify the machine steers to the right 3 Activate steer left and verify the machine 1 Green steers to the left 2 Green Black 3 Blue 4 Blue Black 4 Testthe axle oscillate Refer to Maintenance Section Test the Oscillate Ax
8. Part No 214415 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 135 Service Manual January 2015 Ts Fault Codes Type FXXX Faults DTC Message on Description Possible Causes Failure Mode Number GCON LCD F001 F001 SWITCHFAULT Short circuit of the up limit 1 switch Short circuit of the up limit switch circuit All functions inhibited UP LIMIT1 Bat at system startup Up limit 1 switch short circuit except platform down GCON ECM 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 Down limit 1 switch short circuit except platform down GCON ECM F007 F007 SWITCHFAULT Short circuit of the chassis digital tilt Short circuit of the chassis digital tilt switch circuit All functions inhibited CHASSISTILT BAT switch at system startup Chassis digital tilt switch short circuit except platform down as GCON ECM long as machine is in the elevated position If machine is in stowed position all functionality is resumed F012 F012 SENSORFAULT Short circuit of the Level Pitch Short circuit in the level pitch sensor circuit All functions inhibited LEVEL PITCH Bat Sensor circuit to battery positive Faulty level sensor GCON ECM F013 F013 SENSORFAULT Short circuit of the
9. D1 ENCODER A Sue a CHG LOCKOUT A11 L56B amp la e 9 EN KE 6 BK Rei Ke m Qae 3 gt gt D186SEN BL 7D4 ENCODER B vfu E DOWN LIMIT SW A13 DOCS e DF x te Veta T P o o 8 16 2 P110RET BK S RETURN at s DIAE es Eg NOME y a Sar T S PITORET BK mum In Fiegen 3U2 12V PWR mlaz E o g fo MS 8 t HO T 1 2 DIEET E a o ve eus AGS 4 12 gt f 3 A32RET BK 12 289 BRAKE SINK e IG A w l m a CegTTS nek LS R32BRK WH RD gt gt gt B1 BRAKE SOURCE AER aa 2 C13 LSA20SS RIGHT AXLE Ze C12 a T C26B C26A a 9 3 METODE Fi H i E 3 L S119PS BL L ii DCON U3A or EU PWR ev ES P109PWR GRWH gt RD 13 4 Es EE El SANG WHIBK pipe RIGHTACMOTOR z zz ie STEER SENSOR C9 cms or bn SIT 35 8595 ks OUIBGGENOPHON o seen CONTROLLER GEES GND NPOT C3 P110RET BK 9 BK SENSOR gt 558 5 5 l SE CHE e BL lalalala ora SA els ESSE Elsa I dE i j gt x e eEN va D82CAN YL 8552222855552 3 322555 22 d BE ch D81CAN GR 395 33 dog 98g 2 283 yg y 12 Us gou geegouad g 8252u ug MES SS 38 SG sow DOS GND BA p A ts GER Sodas G gt r8 59 El 3 gt t INVERTER 87A ene 582 SESDE 5 ag CRP T IF OPTION RIBIPWR OR z se S E a S 2 qe ia al RR S Em ER R R195PWR OR RD ares u E R a E O hIG onic ts ai oin w U1 GCON x i TIY T Fe Y ca KEY SW 5 gt 3 MUK qaaskEIirzit
10. esses 151 Fuse Box Layout All Models iese se ee ee a ee enne 152 Ground Control Box Layout All Model 154 Platform Control Box Layout All Models ii se ee ee ee GR AA ee ee ee nono 155 Electrical Schematics ANSI CSA Re RE ER RE ER ER RE ER ER RE ER ER RR Re Ee ER EE 157 Electrical Schematic GS 2669 DC and GS 3369 DC ANSI CSA 158 Electrical Schematic GS 4069 DC ANSI CA 159 Electrical Schematics AS CE sae ee EE RE RR RR RR RE ER RR RE RR RR RR RE RR RR RR Re Ee EE ER 161 Electrical Schematic GS 2669 DC and GS 3369 DC AS CE 162 Electrical Schematic GS 4069 DC AS CE 163 Hydraulic Schemaltics eco erret retener 165 Hydraulic Schematic GS 2669 DC and GS 3369 DC sss 166 Hydraulic Schematic GS 4069 DC 167 Genie xii GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Machine Specifications Fluid capacities Hydraulic tank maximum fill capacity Hydraulic system without outriggers including tank GS 2669 DC Hydraulic system with outriggers including tank GS 2669 DC Hydraulic system without outriggers including tank GS 3369 DC Hydraulic system with outriggers including tank GS 3369 DC Hydraulic system without outriggers including tank GS 4069 DC Hydraulic system with outriggers including
11. t T GA SAL een i DEZCAN YL EFEFEF BEZETSSEBQUS Ze I on DB1GAN GR IFE E 25298552588 as 33 Ig Set slat GND BR Tt SSe EEETET 2 9 Sao Gus x gt ZS ja L aow AUX S83 z 29256 B 10720 lee gt INVERTER T 87A ENABLE O E 5 25583 BEES ros l OPTION gt RISIPWR OR set ga E 402355 i495 IS Jay 1814 ARE ak in os AS 6 87 Ba En ag iid R R LR PWR de el E g ER d ORIG ORIG CR 1 y U1 GCON x gt l i i cn E Ce gt i E KEY SW g S 5 SMARTLINK oaagtbeeszt H war 19 EE M 87A af TS10 SEKR d ddodggdd 2 C16 oso AARDE EN JYT acme S Eee SG EE EEEESSEEEERS prpp pews EE LLE gt are E 2 oo 6 ED tne G2 DIA 857188 u C32BRK WH RD LEERTE GSBOEESS3S lu 4 47 Prioner BK LT a C7 S5zzaYE6S BO DIAT al 38152385 200909 Caba Ek 5 J GND BR 5D6 THERM GND lt 58 SS DIAS Z CREDO c12 amp io OG O Om 4 lt lt FEE ddaEn Ee JA GISAPWARD l w 5 gt C26TSA WH RD 3D3 THERM SENSOR gt BRAKE 419 ESR ER as HE SIBISRISIS RSS PI Rio 9 nu DIAS BK AF BR LEFT 3 g lt b 4 gt D185SEN WH 3D1 ENCODER A PIE DIAT eee raed 4 lv1o1Ro wg AG DRIVE Gg 3 gt D186SEN BL D4 ENCODER B amp wins J en ah de EE as SE MOTOR Q va ee VIPBU RD o a V203RR GRWH O 19 2 gt PHORETBK D5 RETURN DATAZ 4 E BE ID dIe V202LR BLWH P 1 P1988EN RD SDa 12v PWR DI BEZ Weg G i V37SCC BL K i oe ee 5 Keser D ES o E 1 2 E DES X
12. N2 N4 F3 5 Sy m tn Ome z E Kc O OS KE D EI oa 9 oi N J a ec e z SV ml e ks N L e Ut IG e co Genie GS 2669 DC GS 3369 DC GS 4069 DC 155 Part No 214415 Service Manual January 2015 _ EE EE Qu ET Ed _ Platform Control Box Layout All Models 156 157 January 2015 Service Manual EEE Electrical Schematic GS 2669 DC and GS 3369 DC ANSI CSA Service Manual Ho ar Ta EE ORAS January 2015 Electrical Schematic GS 2669 DC and GS 3369 DC ANSI CSA 158
13. Result The platform stops for 4 to 6 seconds D Result The platform does not stop Confirm that the descent delay option has been selected to on Refer to Repair Procedure How to Setup the Machine from Ground Controls Repeat this procedure 4 Lower the platform to the stowed position 5 Push in the red Emergency Stop button to the off position Genie GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Check the Down Limit Switch Height 1 Turn the key switch to platform controls 2 Raise the platform approximately 10 ft 3 m Lower the platform until the down limit switch activates and the platform stops lowering 4 Push in the red Emergency Stop button to the off position 5 Measure the distance between the working surface and the platform deck Checklist C Procedures C 3 Replace the Hydraulic Tank Breather Cap Models with Optional Hydraulic Oil Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first The hydraulic tank is a vented type tank The breather cap has an internal air filter that can GS 2669 63 to 69 inches become clogged or over time can deteriorate If 1 6 to 1 75 m the breather cap is faulty or improperly installed GS 3369 66 to 72 inches impurities can enter the hydraulic system which 1 7 to 183 m may cause component damage Extremely dirty GS 4069 76 to 82 inches Co
14. Solenoid valve 3 position 5 way 350 24V DC with diode schematic item FL Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 93 Part No 214415 Service Manual January 2015 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 Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING 1 Test the coil for resistance Refer to Repair Procedure How to Test a Coil 2 Connect a 10W resistor to the negative terminal of a known good 9V DC battery Connect the other end of the resistor to a terminal on the coil Resistor 100 Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2 9v DC battery 3 100 resistor 4 coil 3 Seta multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 mA 4 Connect the negative lead to the other terminal on the coil 5 Momentarily connect the positive lead from the mu
15. Inspector signature Inspector title Inspector company January 2015 Service Manual A ES Maintenance Inspection Report Model Checklist A Checklist C R A 1 Inspect the manuals C 1 Test platform Serial number and decals overload if equipped A 2 Pre operation C 2 Down Limit Switch Date inspection Descent Delay if equipped A 3 Function tests C Breath del reather cap models Hour meter A 4 Oscillate axle with optional oil R Machine owner Perform after 40 hours Checklist D A 5 30 day service D 1 Wear pads Inspected by print Perform after 150 hours D 2 Hydraulic filter Inspector signature A 6 Drive hub oil D 3 Drive hub oil Inspector title Checklist B D 4 Function pump Inspector company B 1 Batteries Checklist E R B 2 Battery balancer E 1 Hydraulic oil Instructions B 3 Electrical wiring E 2 Wheel bearings e Make copies of this report to use for each inspection B 4 Tires and wheels e Select the appropriate checklist s for B 5 Emergency stop the type of inspection s to perform e Place a check in the appropriate box after each inspection procedure is completed B 6 Key switch Dail 8h A Daily or every 8 hours B7 Hom Quarterly or every A B 250 hours B 8 Drive brakes Semi annually or A B C B 9 Drive speed every 500 hours stowed Annually or A B C D B 10 Drive
16. NS N Y 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 STEER CAL COMPLETE Note If any screens other than the one shown is displayed repeat this procedure If the problem persist contact your local Genie Product Support 14 Use the platform drive controller steer function to turn the steer tires fully to the right 15 Press the Enter button 18 Push in the red Emergency Stop button to the off position Result The ground controls LCD display will show the following 7 SET WHEELS TO N STEER FULL LEFT A PRESS DI AT FULL LEFT Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 105 Service Manual January 2015 Non steer Axle Components 9 1 Drive Motors How to Remove a Drive Motor The drive motors are AC powered and area brushless design requiring very little maintenance They have built in speed and temperature sensors which is monitored by the ground controls GCON The speed sensor is a Hall effect type and is part of the rear motor shaft bearing The temperature switch will shut down the drive motor if it becomes excessively hot 1 Disconnect the battery pack from the machine AWARNING Electrocution burn h
17. 2 Pressand hold the ground control scroll up and scroll down buttons 6 7 8 Ground Control Menu Buttons 1 scroll down button 2 enter button 3 scroll down button 4 escape button 5 LCD display 3 Pull out the red Emergency Stop button to the 9 on position at the ground controls Result The ground controls LCD display will show the following LIFT SETUP TEST SELECT MODEL EI Genie 78 GS 2669 DC GS 3369 DC GS 4069 DC Release the Scroll Up and Scroll Down buttons after the ground controller powers up At the ground controls use the Scroll Up or Scroll Down buttons to scroll to Select Option LIFT SETUP TEST SELECT OPTION 48 Press the Enter button Use the Scroll Up or Scroll Down buttons to scroll to Select Option Pump Efficiency SELECT OPTION f PUMP EFFICIENCY Press the Enter button Result The ground controls LCD display will show the following PUMP EFFICIENCY ENABLE EI Press the Scroll Down button Result The ground controls LCD display will show the following PUMP EFFICIENCY Tf CALIBRATE EI Part No 214415 January 2015 Service Manual 10 Press the Enter button Result The ground controls LCD display will show the following TO START CAL HOLD DOWN EI 11 Press and Hold the Enter button Result The ground controls LCD display will scroll through the following screens Note Con
18. 20 271 27 366 24 325 am 16 23 312 31 42 33 447 44 596 38 515 24 26 352 as 474 37 501 49 664 43 583 zne JM 37 501 49 664 so 678 70 947 61 827 20 41 555 55 745 eo 813 80 1084 68 921 42 L 22 57 773 75 6 80 i 85 90 110 120 Ca e ar F 110 120 122 120 162 1 130 176 1 170 230 1 140 18 1 sm 1 mo f 1s 150 203 160 217 210 284 180 24 ig 139 376 o 230 160 244 240 325 299 on ya 10__ 200 271 270 366 280 378 380 515 320 433 ig 2 298 30 4 319 420 420 seo 350 M aa zm 2 320 433 aso 583 450 6 0 610 s27 510 6n 14 350 474 470 637 500 678 670 908 560759 Fs 480 eso 40 867 eso 922 910 1233 770 1044 az s 718 no 962 750 1016 90 1342 840 na vu PE 590 e00 zeo 1071 oro 1315 1290 1749 1099 1477 e 12 Iere reos 890 1206 1080 1464 1440 1952 1220 1654 7 er s teo 1979 1950 2643 2370 s218 3160 4284 2670 s620 2 3000 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 4 6 Class 8 8 Class 10 9 09 D c U m D 3 L E E D D D i di d D SE o LA SE
19. 48V d 1 I 1 I SES dE Wu iil 027 2 ES0539E EES OIE AE SIE E Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 163 Service Manual January 2015 EE U _ _____ _ ___________ o BB A A Electrical Schematic GS 4069 DC AS CE 164 165 January 2015 Service Manual _ _ _ __ _ _ _ __________ _ _______ _ _ __________ e a Hydraulic Schematic GS 2669 DC and GS 3369 DC January 2015 Hydraulic Schematic GS 2669 DC and GS 3369 DC Service Manual GS 3369 Part No 214415 RESERVOIR
20. B 19 2 gt PHORET BK 3DE RETURN MIPBORD g airis id VERA GAWI o DI ATA E BE Id NE 1 V202LR BLAWH G e 1 gt gt P198SEN AD 2D2 12V PWR DK lt V878CC BUBK ES 3 Kast NEAR L LveotRF OR WH E oH DES V36SCW BL S A E 2001 E BKAWH 1 2 z sa E EX Tit LAANG GR BK y RORRET BK gt gt SB5 BRAKE SINK 25 3 AC PWR DETECT C7 V219AXO GR WH g lt rd du GESANG GRAH 7 L 7 RS2BRK WH IRD 1 gt gt SB7 BRAKE SOURCE u P L L C207RR GR CO5B C25 5 5 2 5 GENERATOR ON p lt af 1 V122AXO0 GRBK Ki gt t ROBLA BL ui C4 lt 7 ro e DCON U3B EEKR PWRHSV ER lt Ya ege Vi21AXO GR er L _lt soairek It gt 6 LEFT AG MOTOR SNCH AS K pf V221FE OR RD PA 6 CONTROLLER fifufis Sin 6 g 028 00106000 GNDINPOT C3 lt x 1 cor Sell 5 9 5 12 314 l Sala C20 2 PLATFORM AG POWER VR R R RA R R R Wie T fr 15 ARR AC yos 3 S ech mm 5 SY vio NE SL VB2APV BURD LSA108 NO No A LSAz0S die fei 2 3 J GND BR 4 LEFT wei NO hos NS RIGHT S8 ANALOG d F30 10A 12 An ARE at ne LEVEL EE E p L F R F Bene y G20A BL7G BYE em SENSOR l s care e m YTA NR RAM jl ome one T BATTERY 24V 40 saw z 5 1 Y10A De l 25A BALANCER 48V TE e WH gt GEI C134PWR RD a os 7 424V 3 C134L0 RD 2 AUX PLATFORM DOWN AAA N OR EA dd 4 FEB G wl BK NE EE SN EN E NOTES mz DOTTED LINES REPRESENT OPTIONS
21. H002 H002 COILFAULT Open circuit in the platform up Short circuit in platform up 1 harness Platform up function PLAT UP1 Open 1 circuit Platform up 1 coil short circuit inhibited GCON ECM H003 H003 COILFAULT Short circuit of the platform up Short circuit in platform up 1 harness All functions inhibited PLAT UP1 Bat 1 circuit to battery positive Platform up 1 coil short circuit except platform down GCON ECM H009 H009 COILFAULT Short circuit of the plattorm down Short circuit in platform down 1 harness All functions inhibited PLAT DOWN1 Bat 1 circuit to battery positive Platform down 1 coil short circuit H027 H027 COILFAULT STEER RT Bat Short circuit of the steer right circuit to battery positive Short circuit in steer right harness Steer right coil short circuit GCON ECM All functions inhibited except platform down HO30 H030 COILFAULT Short circuit of the steer left circuit to Short circuit in steer left harness All functions inhibited STEER LT Bat battery positive Steer left coil short circuit except platform down GCON ECM H043 H043 COILFAULT Short circuit of the brake circuit to Short circuit in brake release enable harness All functions inhibited BRAKE REL Bat battery negative Brake release relay short circuit except platform down GCON ECM H044 H044 COIL FAULT Open circuit in the brake coil circuit Open circuit in brake re
22. LIFT SETUP TEST SELECT MODEL EI i 4 Release the Scroll Up and Scroll Down buttons after the ground controller powers up 5 Use the Scroll Up or Scroll Down buttons to scroll to Machine Options 6 Press the Enter button to select Machine Options Genie 110 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual A ee EA n Outrigger Components 7 Use the Scroll Up or Scroll Down buttons to scroll to Outriggers 8 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 11 Press and hold the Enter button while the system gathers data to calibrate the outrigger level sensor AWARNING Crushing hazard Keep body parts away from outriggers during outrigger movement 12 Continue holding the Enter button after the outrigger level sensor is calibrated The outriggers will retract while the outrigger system gathers and saves data 13 Continue holding the Enter button after the outriggers retract The outriggers will now extend and the system will gather and save data to calibrate the outriggers 14 Continue holding the Enter button after the outriggers extend The outriggers will now retract while the outrigger system gathers and saves data Result The alarms at the ground and platform controls should sound for 1 second The outrigger system is ca
23. NO No PARA EE 3 amg e tae Gg oS l 016 7 l X E 87A 84 TS10 EEES m ogoo22oc g8gz i 22 ei gt Tr SEER Zyret a BEE cz SQ vyer di GESEREBE ER EEEESSEEEESE ppt te GND BN OCET ECE l Ier DI A4 lt N ia 3 2 2 o 85 17 86 E uu uu B Ten or FERFE DIAZ lt EAA C32BRK WH AD SEbDHESESEBoOo Sooo toe eee kh TER PHORETBK y S z xr E LO OOOO Lx BEE rAUUES ENE d J GND BR 3D8 THERM GND 2358 Sp DIRE Z CR60 c12 c2 i lt Se Ses z m i Eccc KA ejgapwa RD n y 5 gt C26TSR Wupp D3 THERM SENSOA g ales BRAKE a EE EER ERE BSP BSR ee A X fme 4 gt D185SEN WH 301 ENCODER A m lt DIIATIZ MN e hg Brio was a pod poa INN EE OLOR Ame 3 D1868EN BL 2D4 ENCODERB 5 DES v8 olei VIPBU RD a latir V203RR GR WH O 16 22 PTIORET BK 2D8 RETURN DT E a O drag LT V202LR BLANH ii 9 1 gt P198SEN RD 5D2 12V PWR DIEET vag te ds V37SCC BUBK E SE i rigid FLV201RF OR WH l 5 Wl KT V36SCW BL y Beta V200LF BKAVH 1 gt R99RET BK 2 gt SBBIBRAKE SINK 35 zz ER dA E T NL BEE er eewer L y R32BRK WHIRD Ja 81 BRAKE SOURCE zu SECH Kat O 8 Bali SEN GR E 1 i5 bog L Cp C25A 5 5 E 5 GENERATOR dia G Konte VEO GR K o i 8 L m E DCON U3B fee Pwaksv ICE Md ES M VA2IAXO GR E EE L LLGao4LF BK LEFT AC MOTOR uu d i P Yos e V221FE OR RD A LL con EE EE beer EPEE GNDINPOT 3 z i coral E ad G 5 C20 C20 2 l POWER TO AC ROWER 7 et FB RFS A Y
24. Open circuit in the outrigger retract coil circuit Open circuit in outrigger retract coil harness Outrigger retract coil open circuit GCON ECM Only outrigger retract function disabled H054 H054 COILFAULT O R RETRACT Bat Short circuit of the outrigger retract coil to battery positive Short circuit in outrigger retract coil harness Outrigger retract coil short circuit GCON ECM All functions inhibited except platform down H057 H057 COILFAULT LF RIGGER Bat H060 H060 COILFAULT LR RIGGER Bat Short circuit of the left front outrigger Coil to battery positive Short circuit of the left rear outrigger Coil to battery positive Short circuit in left front outrigger coil harness Left front outrigger coil short circuit GCON ECM Short circuit in left rear outrigger coil harness Left rear outrigger coil short circuit GCON ECM All functions inhibited except platform down All functions inhibited except platform down H063 H063 COILFAULT RF RIGGER Ba Y Short circuit of the right front outrigger Coil to battery positive Short circuit in right front outrigger coil harness Right front outrigger coil short circuit GCON ECM All functions inhibited except platform down 128 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Baas EE Type HXXX
25. 214415 Service Manual January 2015 DE a Fault Codes GCON UO MAP Ground Controls Circuit Function VO Type Wire Color Pin Number C1 Connector Gray C1 01 ECM Logic Power Power Input RD C1 02 PCON E Stop Power Power Output WH C1 03 PCON E Stop Return Power Input BK C1 04 Link to PCON CAN HI Data Bus YL C1 05 Link to PCON CAN LOW Data Bus GR C1 06 PCON Ground Ground Output BR C1 07 GCON Ground Ground Output BR C1 08 Key Switch PCON Mode Digital Input BK C1 09 Key Switch GCON Mode Digital Input WH C1 10 GCON Emergency Stop Digital Input RD C1 11 Accumulator Pressure Switch Digital Input OR RD C1 12 ECM Driver Power Power Input RD C2 Connector Black C2 01 Platform Up Coil Digital Output OR C2 02 Platform Down Coil Digital Output OR BK C2 03 Steer Left Coil Digital Output BL BK C2 04 Steer Right Coil Digital Output BL C2 05 Oscillate Supply Coil Digital Output GR WH C2 06 Oscillate Right Coil Digital Output GR BK C2 07 Not Used C2 08 Brake Relay CR60 Digital Output WH RD C2 09 Oscillate Left Digital Output GR C2 10 Accumulator Coil Digital Output OR RD C2 11 Not Used C2 12 Not Used Genie ATEREX BRAND 122 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual and EE EE EA aa Fault Codes GCON VO MAP Ground Controls Circuit Function VO Type Wire Color Pin Number C3 Connector Green C3 01 Not Used C3 02 GCON Alarm Digital Outp
26. 4 A q o D ut FRONT 5 e 7 J N ja l N MODELS WITHOUT MODELS WITH OUTRIGGERS OUTRIGGERS 6 Ui Ut BACK BACK 7 f I 8 MJ Genie A TEREX BRAND 154 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 Service Manual January 2015 Platform Control Box Layout All Models e Ut IG He o o y 8 Oloooooo0 O E d e g P2 1 WH oh L STEER BL d P2 2 WH GND BK ENAB SWBLIOR eB BK SNSR GND BK GND YL coo H8 RD 5V RD GND BK E R STEER GR JOY X AXIS YL d o C Ur ER OES ES ii ET H o q g g d o g e E 3 g s E E g G 3 zZ Q a 1 PCON V C9 5 BR ES CAN C9 4 OR CAN C9 3 BL E STOP C9 2 WH PCON V C9 1 RD
27. F 18 C 1300 Flash point None Pour point 81 F 63 C Maximum continuous operating 189 F 87 C temperature Note Use of Chevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie 4 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual AAA AAA EA a ee a E Specifications Hydraulic Component Manifold Component Specifications Specifications Function 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 DOC SAE No 8 50 ft lbs 68 Nm Flow fate 3100 rpm 69pm SAE No 10 55 ft lbs 75 Nm 22 7 L min Function manifold System relief valve pressure 3500 ps maximum 241 bari Lift relief valve pressure 3100 psi GS 2669 DC 214 bar Lift relief valve pressure 2900 psi GS 3369 DC 200 bar Lift relief valve pressure 2850 psi GS 4069 Dc 197 bar Steer relief valve pressure 1500 psi 103 bar Oscillate relief valve pressure 3300 psi 228 bar Steer flow regulator 2 gpm 7 6 L min Oscillate flow regulator 1 gpm 4 L min Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation
28. GS 4069 DC 168 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Scandinavia Phone 0046 3157 5154 Fax 0046 3157 5104 Genie France Phone 0033 237 260 986 Fax 0033 237 260 998 Genie Iberica Phone 0034 935 725 090 Fax 0034 935 725 080 Genie Germany Phone 0800 180 9017 Phone 0049 4221 491 821 Fax 0049 4221 491 820 Genie Australia Pty Ltd Phone 461 7 3456 4444 Fax 61 7 3375 1002 Genie China Phone 86 21 53853768 Fax 86 21 53852569 Genie Sinapore Phone 65 67533544 Fax 65 67533544 Genie Japan Phone 81 3 6436 2020 Fax 81 3 5445 1231 Genie Korea Phone 82 2 558 7267 Fax 82 2 558 3910 Genie U K Phone 0044 1476 584 333 Fax 0044 1476 584 330 Genie Brasil Phone 55 11 4082 5600 Fax 55 22 4082 5630 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566
29. How to Adjust the Platform Up 3 Relief Valve Models with Platform Overload Oo tna Note Verify the hydraulic oil level is within the top l 2 inches 5 cm of the sight gauge om A 1 Connect a 0 to 5000 psi O to 350 bar pressure gauge to test port 1 TP1 on the function manifold 4 5 1 platform up relief valve 2 test port 1 2 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls Genie ATEREX BRAND Manifolds Press and hold the ground control scroll up and scroll down buttons 1 2 3 4 5 EE Oras ww J Ground Control Menu Buttons scroll down button enter button scroll down button escape button LCD display Pull out the red Emergency Stop button to the on position at the ground controls Result The ground controls LCD display will show the following LIFT SETUP TEST SELECT MODEL EI Release the Scroll Up and Scroll Down buttons after the ground controller powers up Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 85 Service Manual January 2015 Manifolds 6 Atthe ground controls use the Scroll Down Note After 1 second the display will return to button to scroll to SELECT OPTION Result The ground controls LCD display will show the following LIFT SETUP TEST 1 SELECT OPTION PLAT OVERLO
30. Part No 214415 Service Manual January 2015 B 1 5 Inspect the Batteries n 4 Genie specifications require that this procedure be 5 performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good 6 engine and machine performance and operational safety Improper fluid levels or damaged cables and connections can result in engine and component damage and hazardous conditions Electrocution burn hazard A WARNING Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Besure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables Genie ATEREX BRAND Checklist B Procedures Be sure that the battery retainers and cable connections are tight Be sure that the battery separator wire connections are tight if equipped Put on protective clothing and eye wear Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 t
31. The ground control LCD display will indicate the software revision and hour meter information After 5 seconds the ground controls LCD display will display machine model and hour meter information again See example below SOFTWARE REV 00000 0 Hours Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position 1 ground control LCD display 2 ground control scroll down button Part No 214415 January 2015 Service Manual 4 2 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 This menu can only be entered from ground controls with the key switch in the ground controls position ININ a3 Tip over hazard Do not adjust function speeds higher than specified in this procedure Setting the function speeds greater than specifications could cause the machine to tip over resulting in death or serious injury ADANGER Tip over hazard This procedure must only be performed by a trained service professional Attempting this procedure without the necessary skills could result in death or serious injury Note Select a test area that is firm level and free of obstructions 1 Turn the key switch to the ground controls p
32. The tilt alarm does not sound and all functions will operate Proceed to step 15 Result The drive function and the lift function 24 will not operate and the tilt alarm will sound at 180 beeps per minute Proceed to step 14 25 Turn the level sensor adjusting nuts just until the level sensor alarm does not sound Lower the platform to the stowed position 26 27 Raise the machine approximately 4 inches 10 cm Remove the blocks from under both wheels Lower the machine and remove the jack zi Center a lifting jack under the drive chassis at the engine side of the machine Raise the machine approximately 4 inches 10 cm Genie GS 2669 DC GS 3369 DC GS 4069 DC January 2015 Place a 2 25 x 10 x 10 inch 5 72 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine Lower the machine onto the blocks Raise the platform approximately 12 feet 3 6 m Result The drive function and the lift function will not operate and the tilt alarm will sound at 180 beeps per minute Result If the tilt sensor alarm does not sound adjust the tilt level sensor until the alarm just begins to sound OR the down limit switch may need to be adjusted Lower the platform to the stowed position Push in the red Emergency Stop button to the off position at both the ground and platform controls Turn the key switch to the off position Raise the machine approximately 4 inches 10 cm Remove the
33. e 5 Que CHG LOCKOUT ATI 2 2 SE BK AC DRIVE i Amp 3 D1868EN BL 2D4 ENCODER B crew z DOWN LIMIT SW AS DOWN LS ge OFF 5 bt dg Jes E vci 9 10 27 PTIORETUK 208 RETURN 2 3 DI A14 lt erg isa Keier Hee Be T MET BG gt PTIORET BK ANS il 9 1 gt P198SEN AD D2 12V PWR DIBAZ a 2 NO We B T w P DIESE E B p Cl 5 NBI FEE RS2RET BK 2B5 BRAKE SINK DEE So LA E H Eg R82BRK WHIRD Bi BRAKE SOURCE E s5 NEEF cia e RIGHT AXLE ie Giz Sa T ooo 3 C268 C26A 3 8 Alcaz oO kk EZ Z E 3 2 S119PS BL L lh DCON U3A Six 3 y PWR 5V 08 P109PWR GR WH RD 13 4 X EE E C175ANG WH BK io RIGHTACMOTOR ZZ gt lt 9 STEER SENSOR C9 C11LFS OR a BL ES ji 335 Em TON D t CONTROLLER LOS EX ES GND NPOT C3 P110RET BK BK SENSOR ooo o lla SESE EELS EA d fl ev 5 3 8 38 e Saez Ese ss S 5S8lS z en A E dl I ovett een ava a D amp 2CAN YL 555322280055 BESEIAAG Eg d M Se G6arRct hee 3599gz2 a2 un Ne ch D8iCAN GR 552 2010026 2612855 aS 88 38 12 soow slak GND BR e TS51 4 SEE PETET 3 9289 E IK E S Iz AUX 94 z S250 4 a Ze lew 1 t 4 INVERTER 487A 6 ENABLE BO amp 25583 Po FE EE IT OPTION RIBIPWR OR i WS S e 2 S gt to E 25 1 Qa Y Ip ay i974 a iz R195PWR OR RD E D y 186 a Y i x E O RIG i ORIG Wo l2 e GR61 H U1 GCON xx Ee i Y le ca KEY SW Ss 2 2 z SMARTLINK q4aabS2zzz2
34. injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless MI You are trained and qualified to perform maintenance on this machine M You read understand and obey e manufacturer s instructions and safety rules e employer s safety rules and worksite regulations e applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC V Service Manual January 2015 Safety Rules Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority A ADANGER AWARNING A CAUTION al Vi Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates a imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation whic
35. 1 217 to 1 173 The battery is approaching the end of it s life Proceed to step 11 Result The difference in specific gravity readings between cells is greater than 0 1 OR the specific gravity of one or more cells is less than 1 177 Replace the battery Genie GS 2669 DC GS 3369 DC GS 4069 DC January 2015 Check the battery acid level If needed replenish with distilled water to 1 8 inch 3 mm below the bottom of the battery fill tube Do not overfill Install the vent caps and neutralize any electrolyte that may have spilled Part No 214415 January 2015 Service Manual Baas __ _ _ ____ A RE Checklist B Procedures B 2 Inspect the Battery Balancer Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first 1 Open the battery compartment and locate the fuse box 2 Locate the LED indicator under the fuse box and watch the LED for 5 seconds to verify the battery balancer condition Mode Led indicator Condition Balanced Green Steady Voltage differential 0 3V Equalizing Green Blinking 1 per sec Voltage differential gt 0 3V Low or Over voltage Green w Orange blinking B to 24V battery pack beyond normal range lt 18V or gt 33V Auto shutdown 1 every 4 seconds Low or Over voltage Green w Orange blinking 24V to 48V battery pack beyond normal range lt 18V or gt 33V Auto shutdown 2 every 4 seconds 24V ci
36. 2 Outrigger Calibration sese ene 110 Platform Overload Components EE Re EE RE EE EE AE EE AE EE RE EER KERE KERE KERE EER EE 112 11 1 Platform Overload System ee ee ee ee ek Re ee Ge Re ee Ge Re ee Ge ke ee ee ke ee ee 112 11 2 Platform Overload Recovery ee ee ee ee ene 116 Tiere Tee e MM 119 GGON died MR AE ted Ate ati ated eed EN 122 Operation Indicator Codes OCH 124 Diagnostic Trouble Codes DICH 124 Troubleshooting HXXX and PXXX Faults ee esse ee se ee ee Re ee Ge ke ee ee ee 125 Fault Inspection Procedure iese ee ee ee ee a i 126 TYPO HAAA OAR EE N EE EE OE DE 128 Type PXXX Faute ees ees es se ee ee ee Re ee ee Ge Re ee Ge Re ee ee ke ee ee ke ee ee Re ee ee nre nns 131 Type UXXKXK STER OR OR OE OE EO EER N 134 Type FAXXA ME EE EE nie EE OE EE N 136 Type CXXX Faults ese ee se ee ee Re ee ee Re ee Ge Re ee ee Re ee ee ke ee ee ee ee Re ee ee ee 141 Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC xi January 2015 BEE a a A y EEES Table of Contents Section 6 AA o oe 143 e 143 Electrical Schematic Abbreviations and Wire Color Legends 144 Hydraulic Component Legend 147 Electrical Symbols Legend 148 Hydraulic Symbols Legend eise ese es se ee ee ee ee Ge de ee ee ee ee ee ee AA ee ee 149 Limit Switch Eegend oo eL tt p Pa EH E MEO aaa 150 Fuse Ground and Platform Control Boxes
37. 2 way valve oscillate supply FG Flow regulator valve controls flow to the oscillate Genie Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 147 Service Manual January 2015 Electrical Symbols Legend 1 a Battery Motor Horn or alarm Flashing beacon Gauge de T F1 CB1 A 25A ASA Diode Coil with suppression LED Fuse with amperage Peat BES a amperage c Connection no Circuits crossing no pK a Quick disconnect prod Level sensor Red emergency stop button normally closed Resistor with onm value Starting aid or glow plug e Power relay terminal connection terminal without outriggers E238 238 86 86 E 30 30 22 21 22 21 use tee NO NC 2p 85 85 R 87A e e nhi uo NO NO Contact solenoid or Button Limit Switch Limit Switch Coil solenoid or relay relay normally open not held held DTE P1 F Lx R14 Mt 100 Mi I Electric motor 148 Genie GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Hydraulic Symbols Legend 0 087 Incn 0 94 mm NS 4 Orifice with size O Check valve Cylinder double acting Accumulator Pump fixed displacement Pump prime mover engi
38. 45 be ed Ce Le GE ie A A id 46 1 2 yide 47 1 3 Platfrom Controls Alarm ee ee se se ee Ee ee GR AA aiaa 48 1 4 Platfrom Emergency Stop Button 48 Platform COMPONENTS ennt terr nn Rain irte citan aan ER RR GR Ke EER KA EE eed 49 2 1 PATO Mi I IRL III REL 49 2 2 Platform Extension Deck 50 Scissor ele E EE 52 3 1 Scissor Assembly GS 2669 DC 53 3 2 Scissor Assembly GS 3369 DO ee ee GR AR Ee ee ee Ee RA Re ee ee ee ee ee 56 3 3 Scissor Assembly GS 4069 DC 60 3 4 Wear Pads tees id id 63 3 5 Litt CYNA E AE EE EE ER EE ER EE 65 Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC ix January 2015 OEE TT Table of Contents Ground Controls ecciesie neon te raten ne tho EKKE eta ran nn ese anuo roD aaa nne DEd EE ke 67 4 1 Software Revision Level emnes 68 4 2 Machine Setup tt t aaa 69 4 3 Auxiliary Platform Lowering mnn 70 4 4 Level Sensor Models without Outriogers eene 70 4 5 Level Sensor Models with Outrtogers esse eed ee ee ee ee ee ee ee ee ee ee 73 4 6 Service Override Mode iis Ee KA Ee KA Ee AA Ee Ke ee ee ee 75 Hydraulic dil EE N EE EE N M 77 5 1 Hydraulic TT eo EE ec veined 71 Ellie ER ME EE EE N N EE EE 80 6 1 Function Manifold Components see ee ee ee se ee Re Ee ee ee Ge Ee Re de ee ee ee ee ee ede ee 80 6 2 Valve Adjustments Function Manifold ie ee ee ee ee ee Ge Re ee Re ee 82 How to Adjust the System
39. 46 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 ess 1 2 Joystick How to Remove the Joystick 1 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 Remove the fasteners securing the platform control box to the platform control bracket Remove the fasteners securing the bottom cover to the platform control box Open the control box Remove the ties securing the joystick wire harness 6 AWARNING 7 8 Service Manual Platform Controls Carefully disconnect the joystick wire harness from the platform controls circuit board Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap Carefully remove the joystick fasteners Carefully remove the joystick from the platform control box Torque specifications Joystick fasteners 9 in lbs 1 Nm Genie Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 47 Service Manual January 2015 Platform Controls 1 3 Platform Controls Alarm How to Rem
40. AA EE RE EE EE 11 Pre Delivery Preparation Report 14 Maintenance Inspection Report 15 Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC vii January 2015 EEE Table of Contents Checklist A Procedures see EE EE EE ER EA Ee EE Ee EE Ke EE Ee AE Ee AE Ee Ke tente nnns 17 A 1 Inspect the Manuals and Decals ii se ee Ee ee AR Re Ee ee ee ee RR de ee ee ee 17 A 2 Perform Pre operation Inspection ie se ee ee AR Re Ee ee ee ee ee de ee rn 18 A 3 Perform Function Tests esee SR Ge ee e 18 A 4 Test the Oscillate Ave 19 A 5 Perform 30 Day Service isse aceite ede e ka Ge Lune dde n sd 20 A 6 Replace the Drive Hub Oil 20 Checklist B ProcedureS mmmcconcoonconanenanonaconaccnnsnnrs oras anno o nro oran sena Ee AE Ee naar naar ranas 21 B 1 Inspect the Batteries eren enitn hn diia 21 B 2 Inspect the Battery Balancer eee 23 B 3 Inspect the Electrical Wiring sen nmm 24 B 4 Inspect the Tires Wheels and Castle Nut Torque iis ee se se Re ee ee 25 B 5 Test the Emergency STOP esse esse ees ee ee ee ee ee Ge ee ek ee ek ee ek ke ee 26 B 6 Test the Key Switch 27 B 7 Test the Automotive style Horn if equipped 27 B 8 Test the Drive Brakes encrenar 28 B 9 Test the Drive Speed Stowed Position ee ee ee AE GR AR Re Ee ee 29 B 10 Test the Drive Speed Raised Position 29 B 11 Check the Module Tray Latch Component
41. All functions inhibited NOT STILL up Right rear DCON ECM P025 P025 PUMPMOTOR Open or short circuit of the P circuit Open or short circuit in pump motor P cable All functions inhibited CURRENT FEEDBK from the right rear drive controller to Faulty pump the pump motor Right rear DCON ECM P026 P026 MOTOR RR Open or short circuit of the U or W Open circuit in right rear drive motor U or W cable All functions inhibited VOLTAGE NOT OK circuit from the right rear drive Right rear drive motor controller to the right rear drive Right rear DCON ECM motor P027 P027 MOTOR LR Open or short circuit of the U or W Open circuit in left rear drive motor U or W cable All functions inhibited VOLTAGE NOT OK circuit from the left rear drive Left rear drive motor controller to the left rear drive motor GCON ECM P028 P028 CONTACTOR Main contactor PR1 stuck in the Short circuit in main contactor harness All functions inhibited STUCK CLOSED closed position Faulty contactor Right rear DCON ECM P029 P029 CONTACTOR Main contactor PR1 stuck in the Open circuit in main contactor harness All functions inhibited DOES NOT CLOSE open position Faulty contactor Right rear DCON ECM P030 P030 COILFAULT Short circuit of the main contactor Short or open circuit in main contactor harness All functions inhibited LC RR Open PR1 coil to battery negative or Faulty contactor open circuit Right rear DCON ECM P031 P031
42. DCON ECM sensor F063 F063 SENSORFAULT Steer angle sensor out of range Short or open circuit of the steer angle sensor Drive performance STEER ANG RANGE Short or open circuit of the steer angle sensor harness reduced Steer angle sensor needs to be calibrated Faulty steer angle sensor Right rear DCON ECM F064 F064 SWITCHFAULT Left axle safety limit switch state not Short or open circuit of the left axle safety and or All functions inhibited LEFT AXLE MISM matching the left axle operational operational limit switches except platform as long as limit switch state Short or open circuit of the left axle safety and or machine is in the elevated operational limit switch harness position Faulty left axle safety and or operational limit switch If machine is in stowed Right rear DCON or GCON ECM position all functionality is resumed F065 F065 SWITCHFAULT Right axle safety limit switch state Short or open circuit of the right axle safety and or All functions inhibited RIGHT AXLE MISM not matching the right axle operational limit switches except platform as long as operational limit switch state Short or open circuit of the right axle safety and or machine is in the elevated operational limit switch harness position Faulty right axle safety and or operational limit switch If machine is in stowed Right rear DCON or GCON ECM position all functionality is resumed Part No 214415 Genie ATEREX BR
43. Examples of these devices are GCON up and down switches and PCON drive joystick Type FXXX Indicate a malfunction associated with machine feedback devices in the electrical system The FXXX faults are divided into short circuit to battery negative short circuit to battery positive open circuit and generic shorts Examples of these devices are limit switches height sensors and pressure transducers Type CXXX Indicate a malfunction associated with controls devices in the electrical system Examples of these devices are platform controls and ground controls ECM Genie 124 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Baas EE i se se Fault Codes Troubleshooting HXXX and PXXX Faults The procedure below illustrates typical steps for diagnosing and fixing faults of type HXXX and POOL Diagnostic Chart No 1 Check the faulted device for a short or open circuit Good Replace faulted device gt Good Y Check short or open circuit of the harness or Ne Repair or replace harness an or 2 p Good connector between Ground Controls and faulted device gt connector Good Y No Good 3 Check GCON Electronic Control Module ECM Replace ECM Wiring Diagram The wiring diagram shown below illustrates how fault type HXXX and PXXX devices are typically wired The signal of these types of devices originates at the Ground Contr
44. Faults continued Service Manual Fault Codes DTC 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 except platform RR RIGGER Bat Coil to battery positive Right rear outrigger coil short circuit down GCON ECM H074 H074 COILFAULT Short circuit of the left front outrigger Short or open circuit in left front outrigger harness Left front outrigger function inhibited LF RIGGER circuit to battery positive negative or Left front outrigger coil short or open circuit open circuit GCON ECM H075 H075 COILFAULT Short circuit of the left rear outrigger Short or open circuit in left rear outrigger harness Left rear outrigger function inhibited LR RIGGER circuit to battery positive negative or Left rear outrigger coil short or open circuit open circuit GCON ECM H076 H076 COILFAULT Short circuit of the right front outrigger Short or open circuit in right front outrigger harness Right front outrigger function inhibited RF RIGGER circuit to battery positive negative or Right front outrigger coil short or open circuit open circuit GCON ECM H077 H077 COILFAULT Short circuit of the right rear outrigger Short or open circuit in right rear outrigger harness Right rear outrigger func
45. 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 C035 C034 DCON LR ECM Valve driver failure of the left rear Left rear DCON ECM Drive functions inhibited FAULT TYPE 03 drive controller C036 C036 DCON RR ECM Right rear drive controller voltage Battery charger connected All functions inhibited FAULT TYPE 04 out of range Batteries to low Right rear DCON ECM C037 C037 DCON LR ECM Left rear drive controller voltage out Battery charger connected All functions inhibited FAULT TYPE 04 of range Batteries to low Left rear DCON ECM C038 C038 DCON RR ECM Capacitor charge failure of the right Open on B or B to the right rear drive controller All functions inhibited FAULT TYPE 05 rear drive controller Right rear DCON ECM C039 C039 DCON LR ECM Capacitior charge failure of the left Open on B or B to the left rear drive controller All functions inhibited FAULT TYPE 05 rear drive controller Left rear DCON ECM C040 C040 DCON RR ECM Open circuit to the PEV B2 circuit Open circuit of the right rear motor controller harness All functions inhibited FAULT TYPE 06 of the right rear drive controller Key switch relay CR61 not closed Right rear DCON or GCON ECM C041 C041 DCON LR ECM Open circuit to the PEV B2 circuit Open circuit of the left rear motor controller harness All functions inhibited FAULT TYPE 06 of the LEF
46. Level Pitch Short circuit in the level pitch sensor circuit All functions inhibited LEVEL PITCH Bat Sensor circuit to battery negative Faulty level sensor GCON ECM F014 F014 SENSORFAULT Short circuit of the Level Roll Sensor Short circuit in the level roll sensor circuit All functions inhibited LEVEL ROLL Bat circuit to battery positive Faulty level sensor GCON ECM F015 F015 SWITCHFAULT Short circuit of the Level Roll Sensor Short circuit in the level roll sensor circuit All functions inhibited LEVEL ROLL Bat circuit to battery negative Faulty level sensor GCON ECM F032 F032 SWITCHFAULT Short circuit of pressure switch to Short circuit in the limit switch harness All functions inhibited OVLD SWITCH Bat battery positive GCON ECM F033 F033 SWITCHFAULT Open or short circuit of pressure Open or short circuit in the limit switch harness All functions inhibited OVLD Open Bat switch GCON ECM F037 F037 SWITCHFAULT Short circuit of the left front outrigger Short circuit of the left front outrigger limit switch Left front outrigger LF RIGGER Bat limit switch to battery positive Short circuit in outrigger harness inhibited if outrigger GCON ECM extend is activated Outrigger can still be retracted F038 F038 SWITCHFAULT Short circuit of the left front outrigger Short circuit of the left front outrigger limit switch Left front outrigger LF RIGGER BAT limit switch to battery negative Short
47. Platform Extension Deck 10 Slide the platform towards the non steer end of the machine until the slider blocks are visible underneath the slider block channel How to Remove the Platform 1 2 3 11 Carefully lift the platform off of the machine and place it on a structure capable of supporting it AWARNING Crushing hazard The platform will become unbalanced and fall it not properly supported Note Note the position of the slider blocks before the platform is removed so that when the platform is installed they will be in the correct position 4 Genie Extension Deck Remove the retaining fasteners from the deck catch and remove the deck catch Remove the retaining fasteners from the deck stop and remove the deck stop Repeat steps 1 and 2 for the other side of the platform bes ss es Ke bs 4 1 deck catch 2 deck stop Remove the platform controls from the platform 50 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Baas EE a A Platform Components 5 Release the four rail Spacers by pulling the 9 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 supportin
48. Properly discard the oil Install the ground control box and fuse box Connect the harnesses Operate all machine functions through a full cycle and check for leaks Check the oil level in the tank and add if needed Install the tank cover plate and install the tank cover plate mounting fasteners E 2 Grease the Steer Axle Wheel Bearings Genie specifications require that this procedure be performed every 2000 hours or every two years whichever comes first Perform this procedure more often if dusty conditions exist Maintaining the steer axle wheel bearings is essential for safe machine operation and service life Operating the machine with loose or worn wheel bearings may cause an unsafe operating condition and continued use may result in component damage Extremely wet or dirty conditions or regular steam cleaning and pressure washing of the machine may require that this procedure be performed more often 1 Loosen the wheel lug nuts Do not remove them 2 Block the non steer wheels then center a lifting jack under the steer axle 3 Raise the machine 6 inches 15 cm and place blocks under the drive chassis for support 4 Remove the lug nuts Remove the tire and wheel assembly Genie GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 a a EE EE EE EE ER A e Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There is no side to
49. Remove an Outrigger Cylinder if equipped Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the mounting fasteners from the inside outrigger cylinder cover Remove the cover 2 Remove the outrigger hose cover Disconnect the outrigger limit switch and cylinder valve connectors 4 Remove the mounting fasteners from the outside outrigger cover Remove the cover 5 Tag disconnect and plug the hydraulic hoses from the outrigger cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Outrigger Components 6 Attach a lifting strap from an overhead crane to the barrel end of the outrigger cylinder for support Do not apply any lifting pressure 7 Remove the outrigger mounting fasteners Slide the outrigger cylinder down and away from the machine A CAUTION Crushing hazard The outrigger cylinder may become unbalanced and fall if not properly supported when removed from the machine Note If the outrigger cylinder is being replaced remove the foot pad assembly and install it on the replacement cy
50. Report The frequency and extent of periodic examinations and tests may also depend on national regulations Failure to perform each procedure as presented and scheduled may cause death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Genie approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 11 Machine Configuration M Unless otherwise specified perform each procedure with the machine in the following configuration e Machine parked on a firm level surface e Key switch in the off position with the key removed e The red Emergency Stop button in the off position at both ground and platform controls e Wheels chocked e All external AC power supply disconnected from the machine e Platform in the stowed position Service Manual January 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 Obey all safety messages that follow this
51. Service Manual 8 4 Oscillate Cylinder How to Remove the Oscillate Cylinder Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the oscillate cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Chock both sides of the wheels at the non steer end of the machine 3 Center a lifting jack under the drive chassis just behind the front axle on the side of the machine the cylinder is being removed from 4 Remove the pivot pin retaining fasteners 5 Using a soft metal drift remove the pivot pin Note Adjust the lifting jack to reduce the load on the pivot pins Do not lift the machine off of the ground 6 Remove the oscillate cylinder from the machine Steer Axle Components 8 5 Oscillate Hoses Test the Oscillate Axle Hose Routing Note Perform this procedure if the oscillate hoses have been removed or replaced 1 Open the ground controls compartment and locate the function manifold
52. blocks from under both wheels Lower the machine and remove the jack Part No 214415 January 2015 Service Manual DEE Ground Controls C5 4 5 Tag and disconnect the wire harness from the Level Sensor Models with level sensor Outriggers 0 0 0 080 0 The Electronic Control Module ECM is programmed to deactivate the lift and drive functions and activate an alarm when a signal is received from the level sensor When the outriggers are stowed the tilt alarm sounds when the incline of the chassis exceeds 2 to the side When the outriggers are deployed functions will be disabled and and fault will be displayed when the incline of the chassis exceeds 0 8 to the side At all times the tilt alarm sounds when the incline of the chassis exceeds 3 to the front or rear 1 ground control box How to Install the Outrigger Level 2 level sensor Sensor 4 Remove the level sensor retaining fasteners ADANGER Tip over hazard Failure to install and remove the level sensor from the or calibrate the level sensor as machine instructed will compromise machine stability and cause the machine to tip over resulting in death or serious injury Do not install or calibrate the level sensor other than specified in this procedure Note Perform this procedure with the machine on a firm level surface that is free of obstructions 1 Turn the key switch to the off po
53. coil to battery Faulty brake relay negative Left or right DCON ECM GCON ECM P041 P041 LOW Charging system fault low power Chargers set incorrectly Batteries will not charge CHARGER POWER SOC monitor correctly Charger harness GCON ECM P042 P042 WRONG Charging system fault wrong profile Chargers set incorrectly Batteries will not charge CHARGER PROFILE SOC monitor correctly Charger harness GCON ECM P043 P043 PWR FAULT Short circuit of the engine run circuit Oil pressure switch closed Engine will continue to run ENGINE RUN Bat to battery negative CR2 short to B with short to B Faulty CR2 relay Faulty fuel valve Faulty voltage regulator VR1 Left rear DCON ECM GCON ECM P044 P044 PWR FAULT Short to battery positive or open Short or open in engine harness Engine will not start and RUN Open Bat circuit of the engine run circuit Left rear DCON ECM run with open circuit GCON ECM Engine will not start and run with short to B PO45 P045 PWR FAULT Short circuit of the engine start circuit CR1 short to B Engine will continue to run START Bat to battery negative Faulty CR1 relay with short to B Faulty starter solenoid Engine will try to start Left rear DCON ECM GCON ECM 132 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Baas EE Fault Codes Type PXXX Faults c
54. i 2 af 4 sre Ne ACCUM a ly el i LEFT AXLE aw 4 Il a y LS6 beet la EK BR 2 cs SENSOR Ce C40 5e tx S Go SWITCH DOWN LS M ERR WH BL 2 csi e e e E A Ai swa sovoLs 033 4 18 2 NO HC y y t cT222Z Y NC HO 7 DIGITAL si l rss T TET6aG05 P RM SE 4 ot g K 033 9 5 LEVEL RD PU gi Eu b DI AZ lt NG Jezek ih o KEY Sages E B He NO SENSOR c14 J GND BR 2D8 THERM GND cuo L AXLE OSG LS A6 cosa CISA HO 7 NG 5 T SWITCH 88 8 SS O ALARM HORN IHG be l 5 C26TSR WH RD gt D THERM SENSOR GEZ z and 5 tc z TET E Si S25 y EID R AXLE OSC LS A5 S223LS YL ES PLAT Z x 1 5 RIGHT m lt p 4 gt D185SEN WH Di ENCODER A she 8 CHG LOCKOUT ATi LS6B amp la 2 SS Ske R AC DRIVE m ime 3 D186SEN BL 5D4 ENCODER B EE w z DOWN L S S OFF ERK l Es MOTOR E Z DOWN LIMIT SW AiS c13 NC B Vers 1 p 2 gt PrioReT Bk 305 RETURN 27 3 oia LEE bee EHE hes to eno S PHORET BK Ln fi 1 P1985EN RD D2 12v PWA oer 2 a E NO NC E 1 2 DI BERE ES e og Ha se ji 3 5 R2RET BK 7 2EB BRAKE SINK pigs Sa LA LE 2 iN AS 3 p PRK WURD gt 281 BRAKE SOURCE E ER ANCE C3 8 Y voa LSA208S RIGHT AXLE E g ele Eg 5 SUSPSBL d x p Q AG a Es 4 C175ANG WH BK DCON U3A Ss B y PWR 48V C8 P109PWR GR WH gt RD 18 4 R E E z S B BIeHTACMOTOR zz gt
55. inner arm Make the chains tight but do not apply lifting pressure AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine 9 Remove the retaining fasteners from the number 3 pivot pins Note Do not remove the external snap ring 10 Using a soft metal drift remove the pivot pins and set aside 11 Carefully lift the linkage assembly off of the machine and place it on a structure capable of supporting it 12 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 2 inner arm Make the chains tight but do not apply lifting pressure 3 Remove the cables from the linkage A WARNING Crushing hazard The linkage assembly assembly could become unbalanced and fall if not Component damage hazard properly supported when Cables can be damaged if they removed from the machine are kinked or pinched Genie 0 Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 53 Service Manual January 2015 Scissor Components 13 Remove the retaining fasteners from the 20 number 2 pivot pins Note Do not remove the external snap ring Remove the two carriage bolts that secure the inner arm and chassis pivot to the steer end of the drive chassis 21 Move the linkage towards the non steer end 14 Using a soft metal drift remove the pivot pins of the machine until the slider feet are clear of and set aside the slider chann
56. installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note This procedure will require an overhead lifting device capable of supporting 1000 lbs 454 g 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Remove the retaining fasteners that attach the ladder to the drive chassis Remove the ladder and set aside 4 Using an overhead lifting device attach a 4 hock sling chain to the ends of the number 4 inner arm Make the chains tight but do not apply lifting pressure AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine 5 Remove the retaining fasteners from the number 5 pivot pins Note Do not remove the external snap ring 6 Using a soft metal drift remove the pivot pins and set aside 7 Carefully lift the linkage assembly off of the machine and place it on a structure capable of supporting it 8 Using a suitable supporting device attach a strap to the rod end of the upper lift cylinder Do not apply pressure 9 Remove the upper cylinder rod end pivot pin retaining fasteners 10 Using a soft metal drift remove the pivot pin 11 Lower the lift cylinder and remove the strap 12 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 4 inner arm Make the chains tight but do not apply lifting pressure 3 Remove the cables from t
57. not apply any lifting pressure 8 Loosen the retaining ring and remove the switch adjustment cover from the pressure switch Note The pressure switch is located on the lower lift cylinder 9 Using a small slotted screwdriver turn the adjustment screw of the platform overload pressure switch one quarter turn into the hydraulic line 10 Push in the red Emergency Stop button to the off position at the ground controls 11 Pull out the red Emergency Stop button to the on position at the ground controls Wait 3 seconds Result The alarm doesn t sound Proceed to step 12 GS 2669 1500lb RX Result An alarm is sounding Repeat this 680 kg procedure beginning with step 9 GS 3369 1000 Ib Note The red Emergency Stop button must be 454 kg cycled after each quarter turn of the nut to allow GS 4069 800 lb the platform overload system to reset 363 kg Note Wait a minimum of 3 seconds between each quarter turn of the nut to allow the platform overload system to reset Genie 112 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 eee Platform Overload Components 12 13 14 15 16 17 18 19 Part No 214415 Remove the supporting device from under the platform Raise the platform to 13 ft 4 m Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position Lower the platform onto the safety arm Install the cover onto the platform overload pr
58. o STEER SENSOR CS GWILFSOR a STER A 5 BEE ______ OUTRIGGEROPTION _ Ch CONTROLLER BSSHUESG GND NPOT C3 PHORET BK BK SENSOR 666 5 ER BRE g EREA KISKE al T i SS DOE oval lee e HHH elias send d Ef moets eEN n D82CAN YL amp nozz2g9292558 882g 495 55552 wis 312 EEEE ERITA 25 gg222205 nis ak uw 9 ees AAI TEIR 2388500042 88 8g 12 w slat GND BR gt Teel 4 EE GESEGSE 2 SORBAS NE ZZ BP 4 en AUX 8838 2 E9285 B ce uy io lee t e 4 E ivERTERI 87A enable Op 8 55585 HEINE ES 00 l OPTION R181PWR OR 10 3 9 al g z 29 HOES 129 Y E Se NES cd uu e A a a R R L R R195PWR OR RD E 85 88 4 i xx B 3 E O RIG onic ES doo te pm CR 1 E U1 GCON x gt see E Ol en KEY SW m E Bi z SMARTLINK a 444 SE z i zt z 3 kr St Ei Je KE la E S cT 87A ag a4 T510 e TERE gt EFE ASA C7 Dr 017 AUX DWN g S AE OTS EEEEaoE EE EEE er GND BN 6 8 ala 2 1 C30 es ep KIC 37 3 4 Dz Aros y sS 555511555533 C29 gt E 28288 e Da7 lt BNE a C32BAKWHRD BSH SS eE8 8 oo SoSEEUS eee kh Ip PrORET BK Jr GND ER 53D6 THERM GND 385 2 DIE Chen CIS EE TES A crac RD 141 5 w _L4 5 gt C28TSR WH RD 2D3 THERM SENSOR 9 y ale BRAKE E SERRERSEEEEER Slab gd LEADER i 5 LEFT ZE 4 gt gt D185SEN WH gt D1 ENCODER A 5 6 DI ATZ ie ITE A O cres V101RO WH BK AG DRIVE Ben 3 D1868EN BL D4 ENCODER B a 5 DIATEZ IP pd qo d Bie WE AD
59. pin 18 Insert the compression spring into the steer sensor and push the tie rod pivot pin up until the actuator hex pin is engaged into the steer sensor Note Be sure the sensor actuator hex pin is engaged into the sensor 19 Rotate the tie rod pivot pin counterclockwise approximately 90 and secure it to the tie rod 20 Install the steer sensor cover 21 Connect the steer sensor harness to the main harness and secure with the cable clamp 22 Calibrate the steer sensor Refer to Repair Procedure How to Calibrate the Steer Angle Sensor Genie ATEREX BRAND Steer Axle Components How to Calibrate the Steer Angle Sensor 1 oA A Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls Press and hold the ground control scroll up and scroll down buttons aa Oras TEE d 1 scroll down button 2 enter button 3 scroll up button 4 escape button 5 LCD display Pull out the red Emergency Stop button to the on position at the ground controls Result The ground controls LCD display will show the following LIFT SETUP TEST SELECT MODEL EI Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 103 Service Manual January 2015 Steer Axle Components 4 Release the Scroll Up and Scroll Down buttons after the ground controller powers up 5 Atthe ground controls use the Scroll Down
60. pivot pin Number 1 outer arm 52 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 3 1 Scissor Assembly GS 2669 DC How to Disassemble the Scissor Assembly AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note This procedure will require an overhead lifting device capable of supporting 1000 Ibs 454 g 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Remove the retaining fasteners that attach the ladder to the drive chassis Remove the ladder and set aside Scissor Components 4 Using a suitable supporting device attach a strap to the rod end of the lift cylinder Do not apply pressure 5 Remove the lift cylinder rod end pivot pin retaining fasteners 6 Using a soft metal drift remove the pivot pin 7 Lower the lift cylinder and remove the strap 8 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 3
61. right rear coil Short circuit in right rear brake harness All functions inhibited BRAKE RR Bat circuit B5 to battery negative Short circuit in right rear brake coil Brake circuit miswired Right rear brake harness miswired Right rear DCON ECM P036 P036 COILFAULT Short circuit of the left rear brake coil Short circuit in left rear brake harness All functions inhibited BRAKE LR Bat circuit B5 to battery negative Short circuit in left rear brake coil Brake circuit miswired Left rear brake harness miswired Left rear DCON ECM P037 P037 BATTERY Battery voltage is out of range at Short or open circuit in voltage sensor circuits All functions inhibited OUT OF RANGE startup Low batteries Faulty battery Battery charger connected to AC power source Left or right DCON ECM P038 P038 DEVICEFAULT Battery pack out of balance Short or open circuit in voltage sensor circuits All functions operate BAT BALANCER Faulty battery balancer Faulty battery Battery terminal corrosion Loose battery terminal GCON ECM P039 P039 DEVICEFAULT Short or open circuit of the brake Short or open circuit in brake relay harness All functions inhibited BRAKE PWR RELAY relay contact or coil Brake relay contact stuck closed Faulty brake relay GCON ECM P040 P040 COILFAULT Short or open circuit of the brake Short or open circuit in brake relay harness All functions inhibited BRAKE PWR OPEN relay contact or
62. speed Short or open circuit of the pump speed sensor All functions operate PUMP Open Bat sensor to battery negative or open Short or open circuit in pump speed sensor harness circuit GCON ECM F051 F051 SWITCHFAULT Short circuit of the accumulator Short circuit of the accumulator pressure switch All functions inhibited ACC PRESS Bat pressure switch to battery positive Short circuit in function manifold harness except platform as long as GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed 052 F052 SWITCHFAULT Short circuit of the accumulator Short circuit of the accumulator pressure switch All functions inhibited ACC PRESS Bat pressure switch to battery negative Short circuit in function manifold harness except platform as long as GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed F053 F053 DCON RR ECM Right rear drive controller thermal Excessive heat Drive speed reduces from THERM PROTECTION protection senses that temperature Faulty thermal sensor in right rear drive controller 185 F 85 C to 221 F has exceeded 185 F 85 C Right rear DCON ECM 105 C Drive inhibited at 221 F 105 C F054 F054 DCON LR ECM Left rear drive controller thermal Excessive heat Drive speed reduces from THERM PROTECTION protection senses that temperature Faulty thermal sensor in left rear drive c
63. tank GS 4069 DC Tires and wheels Wheel lugs Lug nut torque dry Rear Lug nut torque lubricated Rear Specifications Castle nut steer end Castle nut torque 35 ft lbs 47 5 Nm 16 5 gallons 62 5 liters Non marking foam filled RT 16 5 gallons Tire size 26 x 12D380 62 5 liters Tire ply rating 8 18 gallons Tire diameter 26 in 68 liters 66 cm 16 5 gallons Tire width 12 in 62 5 liters 30 cm 18 gallons Weight each 177 5 lbs 68 liters 80 5 kg 17 5 galons For operational specifications refer to the 66 liters Operator s Manual 19 gallons 72 liters Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation 9 5 8 18 170 ft lbs 230 Nm 130 ft Ibs 176 Nm Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 1 Service Manual January 2015 Specifications Performance Specifications Drive speed maximum Platform stowed Forward direction 4 5 mph 7 2 km h 40 ft 6 1 sec 12 2 m 6 1 sec Platform stowed Reverse direction 3 0 mph 4 8 km h 40 ft 9 1 sec 12 2 m 9 1 sec Platform raised 0 3 mph 0 5 km h 40 ft 91 sec 12 2 m 91 sec Braking distance maximum High range on paved surface Gradeability less than 3 ft less than 0 9 m See Operators Manual Function speed maximum from platform controls with maximum rated l
64. 1 Remove the rue ring from the clevis pin connecting the tie rod to the right side yoke assembly Remove the clevis pin Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the hydraulic hoses from the steer cylinder Cap the fittings on the cylinder AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 1 clevis pin 2 Remove the rue ring from each cylinder clevis 2 pivot pin pin Remove the clevis pins 3 steer sensor assembly 3 Remove the steer cylinder from the machine 4 tie rod 5 rue ring 2 Remove the retaining fasteners from the pivot pin connecting the tie rod to the left side yoke assembly 3 Usea small pry bar to move the pivot pin down enough to clear the steer sensor assembly 4 Remove the steer sensor actuator and spring from the tie rod pivot pin and set aside 5 Remove the steer sensor assembly and set it aside 6 Using a soft metal drift pin and a mallet drive the pivot pin up to remove it 7 Remove the tie rod Gri 1 1 98 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015
65. 15 January 2015 Service Manual Checklist A Procedures A 4 4 Drive the left steer tire into a 4 in 10 cm deep Test the Oscillate Axle nale Result All four tires should maintain firm contact with the ground 5 Drive the right steer tire into a 4 in 10 cm Genie specifications require that this procedure be deep hole performed every 8 hours or daily whichever comes first O Result All four tires should maintain firm contact with the ground The oscillate system is designed so that all four tires maintain firm contact to the ground on unlevel Note Verify there are no fault codes shown on the terrain improving traction and machine stability ground control display Proper axle oscillation is essential to safe machine operation If the axle oscillation system is not operating correctly the stability of the machine is compromised and it may tip over Test the Oscillate System stowed position 1 Drive the left steer tire up onto a 4 in 10 cm high ramp Result All four tires should maintain firm contact with the ground 2 Drivethe right steer tire up onto a 4 in 10 cm high ramp O Result All four tires should maintain firm contact with the ground Test the Oscillate System elevated position 3 Push and hold the lift function enable button and raise the platform between 7 ft 213 cm to 9 ft 274 cm Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 19 Service M
66. 17 Remove the retaining fasteners from the number 2 pivot pins Note Do not remove the external snap ring 18 Using a soft metal drift remove the pivot pins and set aside 19 Carefully lift the linkage assembly off of the machine and place it on a structure capable of supporting it 20 Tag and disconnect the harness from the lift cylinder valve block Gen ATEREX BRAND 21 Scissor Components Tag and disconnect the hydraulic hoses from the lift cylinder Plug the hoses and cap the fittings AWARNING Bodily injury hazard Spraying 22 23 hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the hose clamps and hoses from the number 1 inner arm Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 1 inner arm Make the chains tight but do not apply lifting pressure AWARNING Crushing hazard The linkage 24 25 26 pd assembly could become unbalanced and fall if not properly supported when removed from the machine Remove the two carriage bolts that secure the inner arm and chassis pivot to the steer end of the drive chassis Move the linkage towards the non steer end of the machine until the slider feet are clear of the slider channel Carefully lift the linkage assembly off of the machine and place it on a structure capable of su
67. 2015 Manifolds 6 2 Valve Adjustments Function Manifold How to Adjust the System Relief Valve Note Perform this procedure with the machine in the stowed position Note Refer to Function Manifold Component list to locate the system relief valve 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to test port 1 TP1 on the function manifold 2 Remove the platform controls from the platform and place the controls near the function manifold on the hydraulic tank side of the machine 3 Remove the coil from the platform up valve Do not disconnect the harness from the coil 4 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 Press and hold the enable and platform up buttons OR select the platform function button and activate platform up Note the pressure reading on the pressure gauge Refer to Specifications Hydraulic Components Specifications 6 Use a wrench to hold the system relief valve and remove the cap 7 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap A WARNING Tip over hazard Do not adjust the relief valve higher than specified 8 Repeatthis procedure beginning with step 4 to confirm the relief valve pressure 9 Remove the pressure gauge 1 test port 1 2 system relief va
68. 4069 DC 17 Part No 214415 Service Manual January 2015 Checklist A Procedures A 2 Perform Pre operation Inspection Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a Pre operation Inspection is essential to safe machine operation The Pre operation Inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The Pre operation Inspection also serves to determine if routine maintenance procedures are required Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine A 3 Perform Function Tests Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information to perform this procedure is available in the appropriate operator s manual Refer to the Operator s Manual on your machine Genie 18 GS 2669 DC GS 3369 DC GS 4069 DC Part No 2144
69. 7 Fittings swivel nut or hose connection SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 ft lbs 31 2 Nm 8 36 ft lbs 54 2 Nm 10 62 ft lbs 84 Nm 12 84 ft lbs 114 Nm 16 125 ft lbs 169 5 Nm 20 151 ft lbs 204 7 Nm 24 184 ft lbs 249 5 Nm m al Adjustable Fitting a jam nut Non adjustable fitting SAE O ring Boss Port SAE Dash Size Thread Size Flats tube fitting installed into Steel 4 7 16 20 2 SAE Dash Size Torque 6 9 16 18 1 A ORFS 37 Adj 15 ft Ibs 20 3 Nm e 3 4 16 1 ORFS Non adj 26 ft lbs 35 3 Nm ET YT 37 Non adj 22 ft lbs 30 Nm oie EE EE 16 1 5 16 12 1 8 ORFS Adj Non adj 60 ft lbs 81 3 Nm 20 1 5 8 12 1 37 Adj Non adj 52 ftlbs 70 5 Nm 24 1 7 8 12 1 10 ORFS Adj Non adj 100 ft lbs 135 6 Nm 37 Adj Non adj 85 ft lbs 115 3 Nm 12 All types 135 ft lbs 183 Nm 16 All types 200 ft lbs 271 2 Nm 20 All types 250 ft lbs 339 Nm 24 All types 305 ft lbs 413 5 Nm Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC Service Manual January 2015 et Specifications Torque Procedure
70. 8 COILFAULT Short circuit of the oscillate left circuit Short circuit in oscillate left harness All functions inhibited except platform as OSC LEFT Bat to battery negative Oscillate left coil short circuit GCON ECM long as machine is in the elevated position f machine is in stowed position all functionality is resumed Part No 214415 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 129 Service Manual January 2015 Ts Fault Codes Type HXXX Faults continued DTC 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 Oscillate left coil open circuit except platform as long as GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed H090 H090 COILFAULT Short circuit of the oscillate left Short circuit in oscillate left harness All functions inhibited OSCLEFT Bat circuit to battery positive Oscillate left coil short circuit except platform as long as GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed H091 H091 COILFAULT Short circuit of the accumulator Short circuit in accumulator harness All functions inhibited ACCUM Bat circuit to battery negative Accumulator coil sho
71. A20S and LSA20SS platform overload pressure switch S25 SS D 8 6 N Co 9 ollo loo Es right front outrigger limit switch LS13 left front outrigger limit switch LS12 not shown platform down limit switches LS6 and LS6B platform up limit switch LS16 Or Genie gt GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Fuse Box Layout All Models 151 Service Manual January 2015 se Fuse Box Layout All Models A B C D E F G H J K L M Genie A TEREX BRAND 152 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Hs EE HEC EE EE EE Ground Control Box Layout All Models 153 Service Manual January 2015 Ground Control Box Layout All Models A B C D E F G 1 KS1 TERMINAL 2 e o BASE TB P1 pee Z CR61 DEE e EE S Ee creo Gi i ET co E Se av enon
72. AD SELECT OPTION PLAT OVERLOAD SELECT OPTION EI l 10 Press the Scroll Down button to scroll to Down Delay Press the Enter button Result The ground controls LCD display will show the following Result The ground controls LCD display will show the following sELECTOPTION f PLAT OVERLOAD DOWN DELAY ll IS ON TURN OFF 11 Press the Enter button Press the Enter button Result The ground controls LCD display will show the following Result The ground controls LCD display will show the following DOWN DELAY PLAT OVERLOAD IS ON TURN OFF IS ON TURN OFF 12 Press the Enter button Press the Enter button Result The ground controls LCD display will show the following Result The ground controls LCD display will show the following DOWN DELAY PLAT OVERLOAD IS NOW OFF IS NOW OFF Genie GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Manifolds Note After 1 second the display will return to 19 Locate and disconnect the maximum height SELECT OPTION DOWN DELAY limit switch harness SELECT OPTION f Q DOWN DELAY l 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 15 Lift the safety arm move it to the center of the Scissor arm and rotate down to a vertical position 16 Lo
73. AND GS 2669 DC GS 3369 DC GS 4069 DC 139 Service Manual January 2015 Ts Fault Codes Type FXXX Faults continued DTC Message on Description Possible Causes Failure Mode Number GCON LCD F066 F066 MOTOR RR Right rear drive motor torque too Short circuit of the speed sensor harness Drive performance TORQUE TOO LOW low Faulty speed sensor reduced Faulty right drive motor Right rear DCON ECM F067 F066 MOTOR LR Left rear drive motor torque too low Short circuit of the speed sensor harness Drive performance TORQUE TOO LOW Faulty speed sensor reduced Faulty left drive motor Left rear DCON ECM F068 F068 OSCILLATE Oscillate axle safety or operational Open circuit of a safety or operational limit switch All functions inhibited TIMEOUT limit switches failed to close within Open circuit in safety or operational limit switch except platform as long as 4 seconds after opening Right rear DCON or GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed F069 F069 SWITCHFAULT Right and left axle safety or Open circuit of the right and or left axle safety or operational All functions inhibited OSC LIM SWITCHES operational limit switches are in an limit switches except platform as long as open state Open circuit of the right and or left axle safety or operational machine is in the elevated limit switch harness position Righ
74. Bat circuit to battery positive Automotive horn short circuit GCON ECM P007 P007 DEVICEFAULT Short circuit of the GCON alarm Short circuit in GCON alarm harness GCON alram inhibited GCON ALARM Bat circuit to battery negative GCON alarm short circuit GCON ECM P009 P009 DEVICEFAULT Short circuit of the GCON alarm Short circuit in GCON alarm harness GCON alram inhibited GCON ALARM Bat circuit to battery positive GCON alarm short circuit GCON ECM P013 P013 PWRFAULT Short circuit of the PCON power Short circuit in PCON power return harness All functions inhibited PCON PWRET Bat return circuit to battery negative GCON ECM P015 P015 PWRFAULT Short circuit of the PCON power Short circuit in PCON power return harness All functions inhibited PCON PWRET Bat return circuit to battery positive GCON ECM P018 P018 PWRFAULT Short circuit of the PCON power Short circuit in PCON power harness All functions inhibited PCON POWER Bat circuit to battery negative GCON ECM P019 P019 PWRFAULT Short circuit of the PCON power Short circuit in PCON power harness All functions inhibited PCON POWER Bat circuit to battery positive GCON ECM P023 P023 PUMPMOTOR Pump motor voltage out of range Pump voltage to low All functions inhibited VOLTAGE NOT OK Pump voltage to high Right rear DCON ECM P024 P024 PUMPMOTOR Pump motor voltage not still at start Short circuit in pump motor 1 harness to battery negative
75. C045 DCON LR ECM Communication error of the CAN Open or short circuit of the left rear motor controller All functions inhibited FAULT TYPE 09 circuit between the GCON and the harness left rear motor controller Left rear DCON or GCON ECM C048 C048 DCON RR ECM Output error of the thermal sensor Right rear DCON ECM Performance reduced FAULT TYPE 10 circuit of the right rear motor controller C049 C049 DCON LR ECM Output error of the thermal sensor Left rear DCON ECM Performance reduced FAULT TYPE 10 circuit of the left rear motor controller C050 C050 SOC MONITOR State of charge monitor not SOC monitor Performance reduced NOT DETECTED detected SOC monitor harness Incorrect baud rate setting on acuity GCON ECM C053 C053 PCON GCON Software revisions do not match C053 displayed at GCON PCON with older software All functions inhibited SOFTWARE MISMATCH between the PCON and GCON revision connected to GCON with newer software revision C053 displayed at PCON PCON with newer software revision connected to GCON with older software revision 142 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Observe and Obey V Troubleshooting and repair procedures shall Schematics About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard A WARNING Contact with electrically c
76. COILFAULT Short or open circuit of the right rear Short or open circuit in right rear brake harness All functions inhibited BRAKE LC RR Bat brake coil circuit Short or open circuit in right rear brake coil Right rear DCON ECM Part No 214415 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 131 Service Manual January 2015 Ts Fault Codes Type PXXX Faults continued DTC 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 BRAKE LC LR Bat brake coil circuit Short or open circuit in left rear brake coil Left rear DCON ECM P033 P033 COILFAULT Short circuit of the right rear brake Short circuit in right rear brake harness All functions inhibited BRAKE RR Short coil circuit B1 to battery Short circuit in right rear brake coil positive negative Right rear brake harness miswired Brake circuit miswired Right rear DCON ECM P034 P034 COILFAULT Short circuit of the left rear brake coil Short circuit in left rear brake harness All functions inhibited BRAKE LR Short circuit B1 to battery Short circuit in left rear brake coil positive negative Left rear brake harness miswired Brake circuit miswired Left rear DCON ECM P035 P035 COILFAULT Short circuit of the
77. Disconnect the air line from the platform Pull the air line free of the platform Attach a sling chain from the overhead lifting device to the four lifting points on the platform Note This procedure will require an overhead Pi lifting device capable of supporting 1000 Ibs 454 g 1 Remove the cable ties that secures the power to platform wiring to the bottom of the platform Component damage hazard Be 8 sure not to cut the power to the platform wiring Remove the two carriage bolts that secure the platform to the platform pivot at the steer end of the machine 2 Remove the clamp that secures the platform controls cable to the platform 3 Disconnect the platform controls cable from the connector located under the platform 4 Remove the platform controls from the 9 o platform m Component damage hazard The platform controls wiring can f be damaged if it is kinked or L pinched WE oo Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 49 Service Manual January 2015 Platform Components 9 Carefully lift the platform enough to clear the 2 2 platform pivot
78. E si 4 je e E Su 87A 84 iii d ddedssdydSdEE i C15 xa BEE C7 bed C17 IST lar2azrhioti EEEEABABEEEERSE e aup BN cao SET DIA X si SR AUX DWN 5EEEOESWIS 535545355330 T 5x 204s 3 85 86 E omp o B SC 67 E2288 8 DIAZ X rw Reba WHE Tj SEET OOo eo Cotes L 1 4 8 PrioRET BK GND BR D6 THERM GND 365 Sp DIAS lt CR60 C12 amp iot OO090mo d sx Joie i d e ge ui m 4 A CiS4PWR RD LA 5 u 5 gt gt C26TSR WH RD D3 THERM SENSOR 9 y DIAS BRAKE m la selde AR sgle EE ERES ER EE EZ 134 LEFT E 4 gt gt D1858EN WH D1 ENCODER A 5 q DI ATI A b do NB VIOTRO WH BK AGDRNE e az D1868EN BL 3D4 ENCODER B 2 S DI 1 WEE e TOR IS Y8 VIPBURD a ette V203RR GR WH 2 gt gt P110RET BK gt D8 RETURN DZ 1 RELI DEL V202L R BLAWH 1 gt P198SEN RD 93D2 12V PWR DI yar VASC BUBK 5 ery bd trad LV201RF OR WH Er GE vae AU V36SCW BL Y ll GES V200LF BK WH R32RET BK 2 gt gt 5B5 BRAKE SINK z2EL2 5 Stil TEBANG GREK REB WHRD d ccc 2513 A C PWA DETECT 07 lt Y100 V219AXO GR WH Es B E Gene GRWH El EN 207RR GR E ET 5 5 2 6 GENERATOR ON C2 lt Yass Teig 7 4 vtazaxo GR BK o ei Es Ga eh E s 2 1 DCON U3B Ens PWRISBV EET vests VIZIAXO OH zm ES 4 L H cona F BK LEFT AC MOTOR w g e ei Al CEZ voog o v221FE ORIRD GE LY con 6 Iu CONTROLLER 384842333 GNDINPOT 03 z LT ca leas 5 9 11234 I ES ler 153 C20 2 n POWER TO AC
79. GCON ECM function inhibited U018 U018 SWITCH FAULT Short circuit of the PCON low drive Short circuit of the PCON low drive speed switch The machine is limited to PCON LO DRIVE SPD speed switch at system startup GCON ECM low drive speed U019 U019 SWITCHFAULT Short circuit of the PCON low lift Short circuit of the PCON low lift speed switch PCON platform up and PCON LO LIFT SPD speed switch at system startup GCON ECM down functions inhibited U020 U020 SWITCHFAULT Short circuit of the PCON high lift Short circuit of the PCON high lift speed switch PCON platform up and PCON HI LIFT SPD speed at system startup GCON ECM down functions inhibited U021 U021 SWITCHFAULT Short circuit of the PCON up Short circuit of the PCON up directional switch PCON platform up PCON UP directional switch at system startup GCON ECM function inhibited U022 U022 SWITCHFAULT Short circuit of the PCON down Short circuit of the PCON down directional switch PCON platform down PCON DOWN directional switch at system startup GCON ECM function inhibited U023 U023 SWITCHFAULT Short circuit of the PCON outrigger Short circuit of the PCON outrigger enable switch All outrigger functions PCON O R ENABLE enable switc h at system startup GCON ECM inhibited 134 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Type UXXX Faults contin
80. Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 5 Service Manual January 2015 Specifications Battery Specifications J305GH Type 6V DC Quantity 8 Capacity 315 AH Reserve capacity 25A rate 678 minutes Reserve capacity 75A rate 175 minutes Weight each 88 Ibs 40 kg Weight tray with batteries 779 lbs 353 5kg T105 Type 6vDC Quantity 8 Capacity 225 AH Reserve capacity 25A rate 447 minutes Reserve capacity 75A rate 115 minutes Weight each 62 Ibs 28 kg Weight tray with batteries 554 Ibs 251 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Specifications Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok ORFS or 37 JIC fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed Seal Lok Fittings hose end ORFS SAE Dash Size Torque 4 10 ft lbs 13 6 Nm 6 30 ft lbs 40 7 Nm 8 40 ft lbs 54 2 Nm 10 60 ft lbs 81 3 Nm 12 85 ft lbs 115 Nm 16 110 ft Ibs 150 Nm 20 140 ft Ibs 190 Nm 24 180 ft lbs 245 Nm JIC 3
81. HO 87 DIGITAL dde E E 2132500 P A Ae ils Key 8225 a N LEVEL RD PU Sei ce SEI 5 DIAZ lt GR WH iC eec o KEY 5498295 E HS m o SENSOR al CH 4 ND BR D6 THERM GND ER 9 E L AXLE OSC LS A6 rm D 3 ola 7 NG 3 SWITCH 83885 O ALARM HORN IHG iff 5 gt gt C26TSR WH RD 3D3 THERM SENSOR wi S R AXLE RE 293L8 YL 5 x PLAT z LS le 825 y EH OSCLS 4f D D SS PRESSURE RIGHT as 4 gt gt D185SEN WH D1 ENCODER A E 8 K Am LS6B a E KE CARA Eli gum CHG LOCKOUT 2 a 2 eel ii l Y SWITCH AG DRIVE Boe 37 DT86SEN BL 4 ENCODER B feu z DOWN LIMIT SW ATS DOWN LS 8 A corr 3 Vea on IS 1 2 gt gt P110RET BK 3D5 RETURN ot 3 IN etse ME e i Seet af 8 Lo NG 1 2 2 DI ATAS aw sl GND PTIORET BK fi 0 1 gt P198SEN RD 3D2 12V PWR DIBEz B g NO RE 8 io 1 2 DBE EES ue CBS BLY di 3 z gt RS2RET BK 19 2BB BRAKE SINK T morc qo A A y E 2 A L C28TTS RD BK Coon BRK WHIRD BT BRAKE SOURCE E gH AGE EES Y Vels LSA2088 RIGHT AXLE E g 12 Ox x Gamer BL E 25 OO A x dd ES 4 L G175ANG WHK DEON USA S45 Bu PWR 45V CB P109PWR GRWH gt RD 4 313 4 ES ER 3 CG RIGHTACMOTOR f 2 Zz gt gt ie STEER SENSOR CS CITILFS OR LS FER 5 383 3 _ OUTRIGGER OPTION TL CONTROLLER AFTER GND NPOT ES PTIORET BK BK SENSOR o0 r 5 7 Sy E EEE a Ei ARALAR evi s epe lE zi Els ls do
82. How to Disassemble the Scissor Assembly AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications Note This procedure will require an overhead lifting device capable of supporting 1000 Ibs 454 g 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Remove the retaining fasteners that attach the ladder to the drive chassis Remove the ladder and set aside 4 Using an overhead lifting device attach a 4 hock sling chain to the ends of the number 4 inner arm Make the chains tight but do not apply lifting pressure AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine 5 Remove the retaining fasteners from the number 4 pivot pins Note Do not remove the external snap ring 6 Using a soft metal drift remove the pivot pins and set aside 7 Carefully lift the linkage assembly off of the machine and place it on
83. JIC 37 fittings 1 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 T Replace Hie Ong The ang Musi be tight approximately 30 in lbs 3 4 Nm replaced anytime the seal has been broken The O ring cannot be re used if the fitting or 2 Using a permanent ink marker make a hose end has been tightened beyond finger reference mark on one the flats of the hex nut tight and continue the mark onto the body of the Note The O ring in Parker Seal Lok fittings and pee ting en hose end are custom size O rings They are not Pa standard size O rings They are available in the O ring field service kit Genie part number 49612 N Nu 2 Lubricate the O ring before installation 3 Besure the O ring face seal is seated and e retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut NC AN 2 finger tight Illustration 1 5 Tighten the nut or fitting to the appropriate a hex nut torque Refer to the appropriate torque chart b reference mark in this section c body hex fitting 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Gri 8 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Baas EE EA EE EI EE st Specifications 3 Working cloc
84. Lift circuit 20 ft lbs 27 Nm GS 2669 3100 psi 214 bar GS 3369 2900 psi 200 bar GS 4069 2850 psi 197 bar Accumulator FE Oscillate circuit 11 ft lbs 15 Nm Solenoid Valve 2 position 3 way FF Oscillate circuit 20 ft lbs 27 Nm Flow control valve 1 gpm 3 8 L min FG Controls flow to the oscillate 20 ft lbs 27 Nm circuit 7 Relief valve 3500 psi 241 bar FH System relief 20 ft lbs 27 Nm 8 Relief valve 1500 psi 103 bar Fl Steer circuit 20 ft lbs 27 Nm 9 Check valve FJ Load sense 12 14 ft lbs 16 19 Nm 10 Flow control valve 2 gpm 7 6 L min FK Controls flow to the steer circuit 20 ft lbs 27 Nm 11 Solenoid valve 3 position 5 way FL Steer circuit 20 ft lbs 27 Nm Check valve FM 12 Pressure switch FN Oscillate Accumulator 11 ft lbs 15 Nm 13 Solenoid Valve 2 position 3 way FO Lift circuit 25 ft lbs 34 Nm 14 Solenoid Valve 2 position 3 way FP Oscillate right 20 ft lbs 27 Nm 15 Relief valve 3300 psi 228 bar FQ Oscillate relief 20 ft lbs 27 Nm 16 Solenoid Valve 2 position 3 way FR Oscillate left 20 ft lbs 27 Nm Genie 80 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Manifolds 9 E CE FP FN dy G9 m Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 81 Service Manual January
85. Manual Electrical Schematic Abbreviations and Wire Color Legends Item Description Y3 Steer right CW R Resistor Y4 Steer left CCW R1 2k ohm Y5 Drive reverse S Sensor Y7 Platform down S7 Digital level sensor w o outriggers Y7A Platform down GS 4069 models S8 Analog level sensor w outrigger option Y8 Platform up 13 Steer angle sensor Y10 Auxiliary platform down S14 Height angle sensor Plat overload option Y10A Auxiliary platform down GS 4069 models 25 Pressure switch Plat overload option Y33 Left rear outrigger option S26 Lift pump speed sensor Y34 Right rear outrigger option TB Terminal base Ground controls Y35 Left front outrigger option terminal strip Y36 Right front outrigger option TS Toggle switch Y39 Outrigger retract option TS10 Auxiliary down ground Y40 Outrigger extend option TS51 Auxiliary down enable ground Y93 Oscillate left U Electronic Component Y94 Oscillate right U1 GCON ground Y99 Accumulator U2 PCON platform U3A Right DCON U3B Left DCON U4 Battery charger U6 800W inverter option Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 145 Service Manual January 2015 Electrical Schematic Abbreviations and Wire Color Legends Wire Color Legend Color Description BL Blue BK Black BR Brown GR Gr
86. Module ECM is programmed with a Service Override mode Service Override mode is only indented for certain circumstances and is not part of the normal machine operation Service Override mode should only be accessed by trained personal to repair faults and or a malfunctioning machine Note Service Override mode can only be entered at the ground controls and is intended to allow the platform to be raised or lowered Once the platform has reached the maximum allowable height the system will exit Service Override mode Repeat this procedure to lower the platform Note When in Service Override mode an audible alarm will sound Note Before entering Service Override mode fault codes or the malfunction affecting the operation of the machine should be fully understood to ensure Service Override mode is required Note Perform this operation on a firm level surface and if equipped with the outriggers auto leveled or fully retracted Ud Tip over hazard Operating the machine on a surface that is not level while in Service Override mode will result in death or serious injury Follow proper operating procedures and safety precautions Do not use Service Override mode if you are not trained and familiar with the operation of the machine Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 75 Part No 214415 Ground Controls Turn the key switch to the ground controls position and pull out the red Emergency Stop b
87. N 3 i i i EE Ed f 1 tip Ey t BE i Be E 1 i i EE w Sa f 1 pss 2 1 SX Ba SS i E ai T Sug si bi do I EE do ccr Amm ELE Ue LE ENE ccm i z C x bo ene d e EE E Ed IS P ind I A Woy BE e e E z F be as EE EE Aa 2 ZA i 1 oo SO zou fel a Sea r i i Ss 1 i lt l i g x i Zo VE 1 ELL l 1 1 8 20 T it H MTI Z L i i Wo J GO EE 1 o CSN i i i E i I a I o H I i mar ae e 4 9 wk ft LL ME tr DI e ka Lu e oe e a LU ba ul a u tr ul pLe T T TT EE an Ee eae a re aa P II a it EN i ES i A Pee IN T8 I VI 19 II pl I fe EO seg SH g E H i H i N tt II i T pa I pl I i pl Lt D PA A SEE IRR I Lubeke AAA EU celu kn uso nc id kl Tete D rice ae ae esol 1 n fi In S o o o fo 9 L E S E tr ir b S gt u t5 ub a5 Ho EO do ro Genie GS 2669 DC GS 3369 DC GS 4069 DC 166 Service Manual Hydraulic Schematic GS 4069 DC
88. NING EEN the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications How to Test the Hydraulic Pump 2 1 Connect a 0 to 5000 psi O to 350 bar hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the pump mounting bolts Carefully remove the pump pressure gauge to test port 1 TP1 on the AWARNING Component damage hazard function manifold 2 Remove the platform controls from the platform and place the controls near the function manifold on the tank side of the machine 3 Steer the machine fully to the right or left and hold Note the pressure reading on the pressure gauge Refer to Specifications Hydraulic Specifications Genie ATEREX BRAND After replacing the hydraulic pump it is critical to return the lift and drive speed settings to original factory specifications Refer to Specifications Performance Specifications Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 77 Service Manual January 2015 Hydraulic Pump How to Calibrate the Hydraulic 4 Pump 1 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls
89. ODEL EI Release the Scroll Up and Scroll Down buttons after the ground controller powers up Part No 214415 January 2015 Service Manual Manifolds 44 tthe ground controls use the Scroll Down Note After 1 second the display will return to 45 46 47 Part No 214415 button to scroll to SELECT OPTION Result The ground controls LCD display will show the following LIFT SETUP TEST SELECT OPTION Press the Enter button Result The ground controls LCD display will show the following SELECT OPTION PLAT OVERLOAD Press the Enter button Result The ground controls LCD display will show the following PLAT OVERLOAD IS OFF TURN ON Press the Enter button Result The ground controls LCD display will show the following PLAT OVERLOAD IS NOW ON SELECT OPTION PLAT OVERLOAD 48 49 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC SELECT OPTION PLAT OVERLOAD Press the Scroll Down button to scroll to Down Delay Result The ground controls LCD display will show the following SELECT OPTION DOWN DELAY Press the Enter button Result The ground controls LCD display will show the following DOWN DELAY IS OFF TURN ON 89 Service Manual January 2015 Oe Manifolds 50 Press the Enter button How to Adjust the Platform Up O Result The gro
90. POWER o7 lS Ee ERIS Y7 INR V2PBD RD BK you Ayoas CM aga E E PLATFORM i TFT SE NO NO Ee Y10 AN e V52APV BL RD LSA10S LSA20S a S 3 3 Not No 1 1 3 8 1 GND BA LEFT We D Hc a RIGHT amp 8 ANALOG X Ni AXLE AXLE LEVEL Leg L813 mr 90 104 i 12 3 4 cona B c40 SENSOR EE WER us C275 For GE va ANA h So ORIG s JORG BATTERY 24V T J 4 40A mal gt E 1 Y10A oN 6 i e SES ER Ee 2 AUX PLATFORM DOWN 88 7 424V EE C184LO RD L ZZ i ra ZS 1m ek E Nee NE NOTES DOTTED LINES REPRESENT OPTIONS EH ES0539E pM EE DEE eae CMM CE EE EE 4 Genie A TEREX BRAND e Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 159 Service Manual January 2015 EE EE ____ _ gt _ _ ___ gt ____P lt gt E EHH A A Electrical Schematic GS 4069 DC ANSI CSA 160 161 January 2015 Service Manual nt Electrical Schematic GS 2669 DC and GS 3369 DC AS CE Service Manual January 2015 Electrical Schematic GS 2669 DC and GS 3369 DC AS CE
91. RAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC iii Service Manual January 2015 Introduction Serial Number Legend Genie A TEREX BRAND Model GS 3369 Serial number GS6914A 12345 Model year 2012 Manufactur e date 02 19 12 G S69 1 4 A 12345 Electrical schematic number ESOXXX Machine unlade n weight 2 714 Ib 1 231 kg Rated work load including occupants 500 Ib 227 kg Maximu m allowable inclination of the chassis N A Gradeability N A Maximu m allowable side force 100 Ib 445 N Maximum numbe r of platform occupants 2 Country of manufacture USA This machine complies with ANSI A92 6 CAN B354 2 Terex South Dakota Inc 18340 NE 76th Street PO Box 97030 Redmond WA 98052 USA PN 96472 5 model model year facility code for models manufactured in multiple facilities sequence code serial label stamped on chassis serial number inside compartment OO Om E WN Genie A TEREX BRAND iv GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 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
92. Relief Valve see se ee ee se ee ee Re ee ee Re eene 82 How to Adjust the Oscillate Relief Valve iese ee ee ee ee Re ee Re ee ee ee 83 How to Adjust the Steer Relief Valve iese ee se ee ee ee ee Re ee ee Re eene 84 How to Adjust the Platform Up Relief Valve Models with Platform Overload ee ee ee Re Re Ge ee e 85 How to Adjust the Platform Up Relief Valve Models without Platform Overload ee ee Re Ge RA Ge Re ee 90 6 3 Outrigger Manifold Components ees seen 92 0 4 Valve COIS DS 93 Hydraulic Tarik q 95 1 1 Hydraulic KC 95 Steer Axle Components in RE EER GEE EK KERE EE GODE GEDEK ee ER EEN EG ek wek EE EE Ee EEN 96 9 1 Yoke ul EE 96 8 2 Steer Oylinder cementeri RE AGE EE AR Ge Re Ke ee AR Ge Re Ke ee Ge ann ee ke ei 98 9 9 NE ROG ER EE EE OE EO OE OE e OE rra d eu 98 Eed Ete del N ie enc dic 99 8 5 Oscillate HO ES 1 iss esse n Rd dede 99 8 6 Steer Angle Sensor N N 101 Genie D GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 a eee Table of Contents Non steer Axle Components occcccccccccnonononononononononononononononononononononononenenenenenens 106 9 1 Drive Motors ees ees ee se ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee nennen nennen nns 106 9 2 Drive N EE N EE EE p ids 108 Outrigger Components see Re RR RE RE ER AR RE REG RR RE REG RR ANNARA RR RE erre 109 10 1 Outrigger Cylinder EE 109 10
93. Sch Ile 5 ale La on AE gt On Co DIO NJO bd E Q3 N OH N Pay Pa Pan C2 co ez ETT Bl Slolo eol le IN ny Oh olus alo GSF l MEd o a A N EN N io e CO o wech A E EI N o N N w N o Go o a o 00 A Ny md A A A so o N to w N co Q D iy win ls 2 mid LEED Ca Re Ke a R wech al w N N N od co lee IN NIOJN N elo al H Olojo 3 1 525 3 715 970 909 1233 A eo o s lo o m 1 9o o J foo 0 o Sege eA en col en wo Slo IE COIN oo to la oa fos e Nana No co oO tn Elo ln 12 alu foo 0l Go i gt rl 1 c D m D 2 L E G D m D 2 L E c D m D N EE eem ja Q eil a ak t S E Cn Elo lonja AIS ojojo AJ ja ANI o Al Mim co 157 214 210 285 420 570 762 583 791 778 Genie ATEREX BRAND 10 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Scheduled Maintenance Procedures Observe and Obey v v A WARNING HR RN K Part No 214415 Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified of the Maintenance inspection
94. T rear drive controller Key switch relay CR61 not closed Left rear DCON or GCON ECM C042 C042 DCON RR ECM Open circuit of the key switch circuit Open circuit of the right rear motor controller harness All functions inhibited FAULT TYPE 07 or battery positive negative of the Open circuit to B and or B right rear drive controller Key switch relay CR61 not closed Right rear DCON or GCON ECM C043 C043 DCON LR ECM Open circuit of the key switch circuit Open circuit of the left rear motor controller harness All functions inhibited FAULT TYPE 07 or battery positive negative of the Open circuit to B and or B left rear drive controller Key switch relay CR61 not closed Left rear DCON or GCON ECM C044 C044 DCON RR ECM Communication error of the CAN Open circuit of the right rear motor controller harness All functions inhibited FUALT TYPE 08 circuit between the GCON and the Right rear DCON or GCON ECM right rear motor controller C045 C045 DCON LR ECM Communication error of the CAN Open circuit of the left rear motor controller harness All functions inhibited FAULT TYPE 08 circuit between the GCON and the Left rear DCON or GCON ECM left rear motor controller C046 C046 DCON RR ECM Communication error of the CAN Open or short circuit of the right rear motor controller All functions inhibited FAULT TYPE 09 circuit between the GCON and the harness right rear motor controller Right rear DCON or GCON ECM C047
95. TT VaGSCW BL llli l C84ANG GR BK R32RET BK E B5 BRAKE SINK EEEF AG PWR DETECT CZ vioossleN V218AXO GR WH S 3 Dui ee GESANG SO edu Fre WHIRD Gl SETIBRAKE SOURCE SIE GENERATOR ON TS C2 lt voel Jee EE E 8 SEIN 1C207AR OF eege ACA 102 em Mx C205RF OR e DCON USB SEGE PWRISV CB lt EE ta 204LF BK 6 LEFT AC MOTOR uuu Mer 999 V221FE OR RD V cos CONTROLLER Gus el GEEL HEGTE GNDINPOT C3 X z 15 cams 11284 POWER TO AG POWER CHAR RS ARE v RAS C20 VapBD RD BK ZC OS BM d55 Y PLATFORM 1 i 2 SE NO NO e Nard vto LA 2 VS2APV BLAD LSATOS of of LSA208 E Ult 1 4 GND BR LEFT HG bi H d RIGHT S8 ANALOS eu TY 7 Asis AXLE AXLE gj 90 9 gg B Sa C40 SENSOR EE E AE Us m A RAB ORIG ORIG C5 Ge BATTERY 24V aA LE i PRA BALANCER AN Dr ee wes BEUH 3 H I C134PWR RD ker F29 10A TE 7 way 33 C184LO AD m ie dp NOTES r i DOTTED LINES REPRESENT OPTIONS 1 BV l i ei A A S E E R G ES0539E lucro TERRE RU eee A ET LE ELE H Genie A TEREX BRAND 162 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Electrical Schematic GS 4069 DC AS CE
96. Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C 7 5 cSt 104 F 40 C 33 5 Brookfield Viscosity cP 4 F 20 C 1040 cP 22 F 30 C 3310 Flash point 375 F 190 C Pour point 58 F 50 C Maximum continuous operating 171 F 77 C temperature Note An hydraulic oil heating system is recommended when the ambient temperature is consistently below 0 F 18 C Note Do not operate the machine when the ambient temperature is below 20 F 29 C with Rando HD Premium MV Chevron 5606A Hydraulic Oil Fluid Properties ISO Grade 15 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C 5 5 cSt 104 F 40 C 15 0 cSt 40 F 40 C 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating 124 F 51 C temperature 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 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C 8 0 cSt 104 F 40 C 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating 180 F 82 C temperature UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F 65 C 22 cSt 104 F 40 C 46 cSt 0
97. a structure capable of supporting it 8 Using a suitable supporting device attach a strap to the rod end of the lift cylinder Do not apply pressure 9 Remove the lift cylinder rod end pivot pin retaining fasteners 10 Using a soft metal drift remove the pivot pin 11 Lower the lift cylinder and remove the strap 12 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 3 inner arm Make the chains tight but do not apply lifting pressure 3 Remove the cables from the linkage A WARNING Crushing hazard The linkage assembly assembly could become unbalanced and fall if not Component damage hazard properly supported when Cables and hoses can be removed from the machine damaged if they are kinked or pinched Genie 56 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 13 Remove the retaining fasteners from the number 3 pivot pins Note Do not remove the external snap ring 14 Using a soft metal drift remove the pivot pins and set aside 15 Carefully lift the linkage assembly off of the machine and place it on a structure capable of supporting it 16 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 2 inner arm Make the chains tight but do not apply lifting pressure AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine
98. ach type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintenance Procedures section and the Maintenance Inspection Report have been divided into subsections Use the following chart to determine which group s of procedures are required to perform a scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two year or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a minimum of 4 years or in compliance with your employer jobsite and governmental regulations and requirements Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 13 Service Manual January 2015 BEE EE EL EE EE EE a ee EE 02 02 Pre Delivery Preparation Report Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any var
99. ailable at the ground controls amp O When the ECM is in the set up mode the ground controls are used to adjust the function speed parameters machine models or machine options machine setup escape button machine setup scroll up button LCD display machine setup scroll down button machine setup enter button key switch KS1 red Emergency Stop P1 engine start ECM U1 10 platform down button 11 lift function enable button 12 platform up button For further information or assistance consult the Genie Product Support OMAN DOA BOON Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 67 Service Manual EEE es Ground Controls 4 1 Software Revision Level How to Determine the Software Revision Level The machine software revision level is displayed at the ground controls LCD display 1 68 Turn the key switch to the ground controls position Pull out the red Emergency Stop button to the on position at both ground and platform controls Result The display at the platform controls will show CH See example below Lia EN Er 3 LH Result The display at the ground controls will show the machine model and hour meter information See example below READY GS1930 00000 0 Hours Genie GS 2669 DC GS 3369 DC GS 4069 DC January 2015 Press the ground control scroll down button Result
100. anual January 2015 Checklist A Procedures A 5 Perform 30 Day Service The 30 day maintenance procedure is a onetime procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance Perform the following maintenance procedures e BA Inspect the Tires Wheels and Castle Nut Torque e B 14 Check the Oil Level in the Drive Hubs A 6 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 Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may result in component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove the plugs and drain the oil into a suitable container 3 Drive the machine until one of the two plugs is at the highest point 1 drive hub plugs 4 Fillthe hub until the oil level is even with the bottom of the lowest plug hole Refer to Specifications Machine Specifications 5 Install the plugs into the drive hub 6 Repeatthis procedure for each drive hub Genie 20 GS 2669 DC GS 3369 DC GS 4069 DC
101. ars whichever comes first 4 Perform this procedure more often if dusty conditions exist Replacement or testing of the hydraulic oil is 5 essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage 6 Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications refer to Specifications Hydraulic Specifications Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to 9 Specifications Hydraulic Hose and Fitting Torque Specifications 0 11 Genie ATEREX BRAND Checklist E Procedures Push in the red Emergency Stop button to the off position Tag and disconnect the harnesses from the ground control box and the contactor box Remove the ground control box and fuse box retaining fasteners and set aside Remove the both boxes Locate the tank cover plate Remove the tank cover plate mounting fasteners and remove t
102. ase the pressure Install the relief valve cap ADANGER Tip over hazard Failure to adjust the relief valves to specification could result in the machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications 6 Repeat this procedure beginning with step 3 to confirm the relief valve pressure 7 Lower the platform to the stowed position Using a suitable lifting device remove the weight from the platform Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 91 Service Manual January 2015 ese AD Manifolds 6 3 Outrigger Manifold Components The outrigger manifold is located inside the hydraulic compartment Index Schematic No Description item Function Torque 1 Solenoid valve 3 position 4 way BA Outriggers extend retract 20 25 ft lbs 27 34 Nm SCS ED Y Gri o 1 1 92 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 6 4 Valve Coils How to Test a Coil A properly functioning coil provides an electromagnetic force which operates the solenoid valve Critical to normal operation is continuity within the coil Zero resistance or infinite resistance indicates the coil has failed Since coil resistance is sensitive to temperature resistance values outside specification can produce erratic operation When coil resistance decreases below specification a
103. atform overload system regularly is essential to safe machine operation Continued use of an improperly operating platform overload system could result in the system not sensing an overloaded platform condition Machine stability could be compromised resulting in the machine tipping over 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls 2 Raise the platform approximately 10 feet 3m 3 Liftthe safety arm and move it to the center of the linkage and rotate to a vertical position 4 Lower the platform onto the safety arm Turn the key switch to the off position 6 Locate and remove the maximum height limit switch from the lower slider channel and set aside Note Do not disconnect the limit switch harness Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 33 Part No 214415 Checklist C Procedures 1 maximum height limit switch Turn the key switch to ground control and fully raise the platform Result The platform should stop raising and an alarm should sound A fault of platform overloaded should be present on the ECM diagnostic display window at the ground controls Result The platform continues to raise OR an alarm does not sound OR a fault is not present on the ECM diagnostic display window at the ground controls Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped Se
104. azard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 2 Chock both sides of the wheels at the steer end of the machine 3 Center a lifting jack under the drive chassis at the non steer end of the machine 4 Loosen the wheel lug nuts Do not remove them 5 Raise the machine approximately 2 inches 5 cm Place blocks under the chassis for support AWARNING Crushing hazard The chassis will fall if not properly supported 6 Remove the wheel lug bolts Remove the tire and wheel assembly 7 Remove the axle cover 1 axle cover 2 drive hub 3 axle assembly 8 Tag and disconnect the electrical connectors for the brake speed and temperature sensors at the drive motor 9 Tagand disconnect the electrical connectors for the oscillate limit switches 10 Tagand disconnect the drive motor power cables from the motor controller in the ground controls compartment Note The power cables will have to be pulled through the drive chassis when the axle assembly is removed Genie 106 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 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 Remo
105. button to scroll to SELECT OPTION LIFT SETUP TEST SELECT OPTION 48 6 Press the Enter button Use the Scroll Up or Scroll Down buttons to scroll to Select Option Steer Sensor SELECT OPTION STEER SENSOR 8 Press the Enter button Result The ground controls LCD display will show the following STEER SENSOR IS ON TURN OFF Note Do not press the Enter button Pressing the Enter button will disable the steer sensor 9 Use the Scroll Up or Scroll Down buttons to scroll to Calibrate Steer Sensor CALIBRATE t STEER SENSOR 10 Press the Enter button Result The ground controls LCD display will show the following Note The platform controls do not have to be connected at the chassis ground controls PCON CONNECTED AT CHASSIS EI 11 Press the Enter button Result The ground controls LCD display will show the following SET WHEELS TO STEER CENTER 7 W PRESS EI AT CENTER N J 12 Use the platform drive controller steer function to align the steer tires with the drive chassis Genie 104 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 13 Press the Enter button Result The ground controls LCD display will show the following E SET WHEELS TO S STEER FULL RIGHT gt y PRESS e AT FULL RIGHT
106. circuit in outrigger harness inhibited if outrigger GCON ECM extend is activated Outrigger can still be retracted F039 F039 SWITCHFAULT Short circuit of the right front Short circuit of the right front outrigger limit switch Right front outrigger RF RIGGER Bat outrigger limit switch to battery Short circuit in outrigger harness inhibited if outrigger positive GCON ECM extend is activated Outrigger can still be retracted a Genie 136 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Baas EE ER A Type FXXX Faults continued Fault Codes DTC Message on Description Possible Causes Failure Mode Number GCON LCD F040 F040 SWITCHFAULT Short circuit of the left rear outrigger Short circuit of the left rear outrigger limit switch Left rear outrigger RF RIGGER BAT limit switch to battery negative Short circuit in outrigger harness inhibited if outrigger GCON ECM extend is activated Outrigger can still be retracted F041 F041 SWITCHFAULT Short circuit of the left rear outrigger Short circuit of the left rear outrigger limit switch Left rear outrigger LR RIGGER Bat limit switch to battery positive Short circuit in outrigger harness inhibited if outrigger GCON ECM extend is activated Outrigger can still be retracted F042 F042 SWITCHFAULT Short circuit of the left rear outrigger Short circuit of the left rear outrigger limit swi
107. control box Open the control box 5 Remove the ties securing the wire harness 6 Disconnect the red and black wires from the alarm 7 Carefully remove the alarm from the platform control box 8 Carefully disconnect all wire harness connectors from the platform controls circuit board A WARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 9 Carefully remove the platform controls circuit board fasteners 10 Carefully remove the platform controls circuit board from the platform control box 11 Remove the transparent caps from the platform controls circuit board and save Circuit board fastener torque specifications lt 5 in Ibs lt 0 6 Nm Hand tighten until screw seats Note Before installing a circuit board place the transparent caps removed in step 11 over the circuit board buttons Note After installing the circuit board check for proper button operation Excessive torque of the circuit board fasteners will cause the buttons to bind Moderate torque of the circuit board fasteners will not allow the buttons to engage Genie
108. e i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 6 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 7 Continue at full speed and note the time when the machine reference point crosses the finish SEET line Refer to Specifications Performance Specifications Genie III Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 29 Service Manual January 2015 Checklist B Procedures B 11 Check the Module Tray Latch Components Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the module tray latch components in good condition is essential to good performance and service life Failure to detect worn out latch components may result in module trays opening unexpectedly creating an unsafe operating condition 1 Open both module trays and lubricate each module tray latch Using light oil apply a few drops to the side of the latch mechanism 2 Inspect for and tighten any loose fasteners B 12 Check the Electrical Contactor Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the electrical contactor in good condition is essential to safe machine performance Failure to locate a worn or damaged contactor could result in unsafe operating conditions a
109. e linkage assembly off of the machine and place it on a structure capable of supporting it Genie 62 GS 2669 DC GS 3369 DC GS 4069 DC center pivot pins Note Do not remove the external snap ring Using a soft metal drift remove the center pivot pins and set aside Carefully lift and separate the linkage assembly apart and place it on a structure capable of supporting it Part No 214415 January 2015 Service Manual 3 4 Wear Pads How to Replace the Scissor Arm Wear Pad Platform Scissor Arm Slider Blocks 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Remove the slider blocks and discard 3 Install the slider blocks Note When installing the platform the drill holes in the slider blocks must be on the top and bottom T p P SR Ez s N T a A Bu N 4 Install the platform Chassis Scissor Arm Wear Pads 1 Attach a lifting strap from a suitable lifting device to the ladder at the non steer end of the machine Support the ladder Do not apply lifting pressure Scissor Components 2 Remove the fasteners securing the ladder to the chassis Remove the ladder from the machine and set aside AWARNING Crushing hazard The ladder could fall if not properly supported when the fasteners are removed from the machine 3 Using an overhead lifting device attach a strap to the 1 inner arm at the non stee
110. e spindle Component damage hazard Do not apply excessive force or damage to the lip of the seal may occur Place the outer bearing into the hub Install the spindle washer thrust washer and castle nut Tighten the slotted nut to 150 ft lbs 203 Nm to seat the bearings Fully loosen the castle nut and re tighten to 35 ft lbs 48 Nm Install a new cotter pin Bend the cotter pin to lock it in place Note Always use a new cotter pin when installing a castle nut 23 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 41 Install the dust cap Service Manual January 2015 A esese e ee This page intentionally left blank Gri 42 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Observe and Obey Ed v Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start v NAN Part No 214415 Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and parts are available and ready for use Use only Genie approved replacement parts Read each procedure completely and adhere to the instructions Attempting s
111. ed function enable platform KS1 Key switch BN4 Platform down Outrigger extend platform L LED or Light BN5 Horn platform L12 Left front outrigger option platform BN6 Outrigger enable option platform L13 Right front outrigger option platform CB Circuit breaker L14 Left rear outrigger option platform CB2 7 amp controls L15 Right rear outrigger option platform CB7 15 amp power LS Limit switch CR Control relay LS6 Platform down operational CR60 Brake release LS6B Platform down safety CR61 Key switch LS12 Left front outrigger option CT Contact type limit switch LS13 Right front outrigger option N O Normally open LS14 Left rear outrigger option N C Normally closed LS15 Right rear outrigger option N O H C Normally open held closed LS20 Platform full height CE models N C H O Normally closed held open LSA10S Left axle oscillate operational F Fuse LSA20S _ Right axle oscillate operational F9 50 amp 800W inverter option LSA10SS Left axle oscillate safety F27 30 amp 48V DC battery charger LSA2OSS Right axle oscillate safety F28 5 amp 24V DC battery balancer M Motor or Pump F29 5 amp 48V DC battery balancer M5 Lift pump FB Flashing beacon P Red emergency stop button FB1 Option P1 Ground controls P2 Platform controls PS Pressure switch PS5 Accumulator PR Solenoid relay PR1 Primary contactor Genie 144 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service
112. een OR Orange PP Purple RD Red WH White YL 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 White Red WH YL White Yellow YL BK Yellow Black Genie 146 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Baas EE AA EE ANN Hydraulic Component Legend Service Manual BA 3 position 4 way directional valve FH Relief valve main system outrigger cylinders extend retract option Fl Relief valve steer circuit CA S Pur 2 way valve platform down all FJ Check valve load sense circuit CB 2 position 2 way valve platform down EIS je En AE GS 4069 CC 2 position 2 way valve LR outrigger FL 3 position 5 way valve steer right left option FM Check valve load sense circuit CD 2 position 2 way valve RR outrigger FN Pressure switch option FO 2 position 3 way valve platform up CE GEN 2 way valve LF outrigger FP 2 position 3 way valve oscillate left option E FQ Relief valve oscillate circuit CF 2 position 2 way valve RF outrigger i position 3 way valve oscillate rig option FR 2 tion 3 llat ht FA Check valve blocks flow to tank oscillate circuit FB Relief valve Platform up circuit accumulator supply FC Orifice accumulator circuit FD Relief valve Platform up circuit FE Accumulator FF 2 position
113. el 15 Carefully lift the linkage assembly off of the 22 Carefully lift the linkage assembly off of the machine and place it on a structure capable of machine and place it on a structure capable of supporting it supporting it 16 Tag and disconnect the harness from the lift Separate the link sets cylinder valve block 1 Using an overhead lifting device attach a 17 Tag and disconnect the hydraulic hoses from the lift cylinder Plug the hoses and cap the fittings A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 18 Remove the hose clamps and hoses from the 4 hook sling chain to the ends of the inner arm Make the chains tight but do not apply lifting pressure AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine Remove the retaining fasteners from the center pivot pins number 1 inner arm Note Do not remove the external snap ring 19 Using an overhead lifting device attach a 3 4 hock sling chain to the ends of the number 1 inner arm Make the chains tight but do not apply lifting pressure 4 AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine Genie Using a soft metal drift remo
114. enie A TEREX BRAND Serial Number Ran ge GS 2669DC GS 3369DC GS 4069DC from GS6912 1300 Part No 214415 Rev D1 January 2015 Service Manual January 2015 Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure This manual provides detailed scheduled maintenance information for the machine owner and user It also provides troubleshooting and repair procedures for qualified service professionals Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Genie dealer service center Compliance Machine Classification Group B Type 3 as defined by ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Genie policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Genie of errors and send in suggestions for improvement All communications will be carefully considered for
115. ensor 6 Remove the steer sensor cover assembly 9 Remove the steer sensor actuator and spring from the tie rod pivot pin and set aside Note Inspect the steer sensor actuator to make sure it is not broken or twisted Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 101 Service Manual January 2015 Steer Axle Components 10 11 102 Remove the steer sensor assembly retaining fasteners Remove the steer sensor assembly from the yoke Set the spacer plate aside steer sensor cover spacer plate steer sensor bracket cable restraint steer sensor steer sensor spacer steer sensor mounting plate NOOR GO MM 12 13 14 15 Pull the sensor harness through the cable restraint and sensor bracket Remove the retaining fasteners that secure the steer sensor and the sensor spacer to the mounting plate Remove the steer sensor Install the new steer sensor Install the steer sensor assembly to the yoke Rotate the tie rod pivot pin until it is approximately 90 from the mounting tab on the tie rod Genie GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 17 Install the steer sensor actuator onto the tie rod pivot
116. ent damage Dealer service is strongly recommended A WARNING Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform Refer to Repair Procedure How to Remove the Platform Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 65 Part No 214415 Service Manual January 2015 Scissor Components 2 Disassemble the scissor assembly Refer to Repair Procedure How to Disassemble the Scissor Assembly GS 4069 DC 1 platform down solenoid valve 2 upper lift cylinder 3 lower lift cylinder 4 pressure switch AS CE models Gi 66 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 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 O The ground controls consist of an Electronic Control Module ECM emergency stop button key switch and circuit breaker O Activating the function enable button and the up or down at the same time sends a signal to the ECM This allows the platform to be raised or lowered at the ground controls Note Steer and drive functions are not av
117. ent damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to 17 Remove the steer cylinder rue ring and clevis Specifications Hydraulic Hose and Fitting Torque pin from the yoke and set aside Specifications 18 Remove the tie rod rue ring and clevis pin 1 Refer to Repair Procedure How to Remove from the yoke and set aside the Yoko 19 Remove the retaining fastener from the lower 2 Remove the drive motor mounting fasteners yoke king pin Remove the drive motor from the yoke 20 Use a small pry bar to remove the king pin 21 Remove the retaining fastener from the upper yoke king pin 22 Use a small pry bar to remove the king pin 23 Remove the yoke assembly from the machine A CAUTION Crushing hazard The assembly may become unbalanced and fall if not properly supported and secured with a suitable lifting device when it is removed from the machine Genie 0 0 0 0 Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 97 Service Manual January 2015 Steer Axle Components 8 2 8 3 Steer Cylinder Tie Rod How to Remove the Steer How to Remove the Tie Rod Cylinder
118. ential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often A CAUTION Bodily injury hazard Beware of hot oil Contact with hot oil may cause severe burns 1 Remove the filter with an oil filter wrench Clean the area where the hydraulic oil filter meets the filter head AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Note The hydraulic filter is mounted on the hydraulic tank Genie 36 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 2 Apply a thin layer of fresh oil to the new oil filter gasket 3 Install the new filter and tighten it securely by hand 4 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter 5 Clean up any oil that may have spilled during the replacement procedure 6 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both the ground and platform controls Start the engine 7 Raisethe platform approximately 3 feet 1 m 8 Inspect the filter and related components to be sure that there are no leaks Chec
119. es listed in the Diagnostic Trouble Code Charts describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected Models are listed below each code to assist in the troubleshooting codes for a specific model Genie 120 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Genie SmartLink Diagnostic 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 The Ground Controls will display a brief description of the code at the LCD display as well Refer to the GCON I O Maps Operational Indicator Codes OIC and Diagnostic Trouble Codes DTC in this section to assist in troubleshooting faults Fault Codes GCON ECM Connector Layout Rear of Ground Controls ECM models without outriggers Z 9 smartLInk C4 C2 C1 C8 VERRE n p IRIS ake EIER EA Be le E d p Brown Black Gray Green Rear of Ground Controls ECM models with outriggers Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 121 Part No
120. essure switch or switch box and securely tighten the cover retaining fasteners Do not over tighten Apply Sentry Seal to one of the cover retaining fasteners where it contacts the platform overload pressure switch box Raise the platform and rotate the safety arm to the stowed position Lower the platform to the stowed position Service Manual Check the Maximum Height Limit Switch 1 Using a suitable lifting device place a test weight in the center of the platform floor Secure the weight to the platform Refer to the chart below GS 2669 1500 Ib 680 kg GS 3369 1000 Ib 454 kg GS 4069 800 Ib 363 kg 2 Raise the platform to approximately 13 ft 4m 3 Rotate the safety arm away from the machine and let it hang down 4 Raise the platform until it activates the maximum height limit switch Result The platform should stop raising and the alarm does not sound Proceed to step 7 D Result The platform continues to raise OR the alarm sounds Proceed to step 5 5 Lower the scissor assembly until the safety arm rest on the cross tube 6 Adjust the maximum height limit switch by moving it towards the non steer end of the machine Repeat this procedure beginning with step 2 7 Lower the platform enough to return the safety arm to the stowed position Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 113 Service Manual January 2015 Platform Overload Components 8 Lowe r
121. from the Emergency Stop base Electrocution burn hazard A WARNING Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 6 Carefully remove the Emergency Stop base from the Emergency Stop button 7 Carefully remove the retaining ring from the Emergency Stop button 8 Carefully remove the Emergency Stop button from the platform control box Lo Qanie 48 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 2 1 5 Platform Platform Components Remove the cover from the AC outlet Tag and disconnect the wiring from the outlet AWARNING Electrocution burn hazard How to Remove the Platform AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a 6 suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and 7 significant component damage Dealer service is strongly recommended Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Models with air line to platform option
122. future printings of this and all other manuals Contact Us Internet www genielift com E mail awp techpub terex com Genie i GS 2669 DC GS 3369 DC GS 4069 DC Find a Manual for this Model Go to http www genielift com Use the links to locate Operator s Parts or Service Manuals Copyright 2011 by Terex Corporation 214415 Rev D1 January 2015 First Edition Fourth 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 Part No 214415 January 2015 Service Manual AA AAA AA es Introduction Revision History Revision Date Section Procedure Schematic Page Description A 7 2012 New release B 8 2012 2 Spec Hyd Comp Spec 4 Repair 5 1 6 1 6 Schem 6 22 6 23 C N A N A Not Released D 12 2013 3 Maint Section 3 4 Repair Section 4 5 Diag Section 5 6 Schem Section 6 D1 1 2015 Spec Updated Machine Specifications Repair Added 11 2 Platform Overload Recovery Fault Codes Updated GCON UO Map Schematics All Electrical Schematics Reference Examples Section Maintenance B 3 Section Repair Procedure 4 2 Electronic Version Section Diagnostics All charts Click on any content or procedure in the Table of Contents to view the update Section Schematics Legends and schematics Genie ATEREX B
123. g S i i z e Zo 1 5 ee ER TTT ED LL E ze 0 l o E 3 l ali 3 A H El od 5 E 8 u g ot I 2 283 3 5 Se 3 8 DO I lt 1 I Q x a a LR ERU gen im E CA 2 L el e e g AI By g 9 GE E SL 33 T TA gt ge a2 5 id lei i o E o gt eo i VI 1 ind Ld AO CR E pi i LU H O 1 e i 1 EE Ty f gt L s E I 1 I Ba goo EE 433 y ge L eS z i E g 1 A Sei Sd ERE I ps I ee E 7 1 GC dy Qi f PENES de i 1 AA E PEA DAS O sf o ha Ze SE 9 uc z I la Tr Ia E Tay Q 1 1 1 02 1 A e 1 T e e I I E lt z lu z E pl pa a eee i S 222 m lt m c ZO A Sui E i i ru Zod fiz o Des A i BA rA d Hen d E iA el i i i 2 l j os TE Ss DE 8 S 2060 BN IE GLAS 2 ol 1 I xE ho 10209 0 d I PSA i H 8 i A AGE i E Sr E ag x 3 Su o SE TE EEN re ii d H LA e r mar wa 4 LL tt H m a tt LL ul e e e tc LU e LU tr W Y33 R F OUTRIGGER L F OUTRIGGER R R OUTRIGGER LR OUTRIGER Service Manual January 2015 pu _ gt _ ____ a __ _ ___e_____ _ Hydraulic Schematic
124. g it AWARNING Crushing hazard The platform extension will become unbalanced and fall when removed from the machine if not properly supported and secured to the forklift 1 rail spacer 6 Position a forklift at the steer end of the machine with the forks even with the bottom of the platform extension 7 Carefully slide the platform extension out until the platform extension makes contact with the carriage on the forklift 8 Secure the platform extension deck railings to the carriage of the forklift to support the platform extension deck Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 51 Service Manual January 2015 Scissor Components 7 N GS 2669 Steer End Platform pivot Number 3 outer arm Lift cylinder rod end pivot pin Number 3 pivot pin steer end Number 2 center pivot pin Qty 2 Number 2 pivot pin steer end Number 1 center pivot pin Qty 2 ANSI CSA Number 1 center pivot pin Qty 1 AS CE Number 1 inner arm NOOR WD o Genie 10 11 12 13 14 15 16 17 18 19 Non steer End Chassis pivot Slider block Qty 2 Number 3 inner arm Number 3 center pivot pin Qty 2 Number 3 pivot pin non steer end Number 2 inner arm Number 2 outer arm Number 2 pivot pin non steer end Lift cylinder barrel end
125. h if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority M Genie GS 2669 DC GS 3369 DC GS 4069 DC Be sure to keep sparks flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure any forklift overhead crane or other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure that fasteners intended for one time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be s
126. harged circuits could result in death or serious injury Remove all rings watches and other jewelry be completed by a person trained and qualified on the repair of this machine before operating the machine Before Troubleshooting M Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine V Be sure that all necessary tools and test equipment are available and ready for use V Immediately tag and remove from service a damaged or malfunctioning machine V Repair any machine damage or malfunction Hydraulic Schematics A WARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 143 Service Manual January 2015 Electrical Schematic Abbreviations and Wire Color Legends Item Description H2 Horn B Battery H5 Multi function alarm ground B7 48V DC Battery pack H8 Alarm platform BN Button Jc Hall effect controller BN1 High speed function enable platform JC3 Drive Steer BN2 Platform up Outrigger retract platform KS Key switch BN3 Low spe
127. hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container on the platform 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition D Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or is illegible Remove the machine from service until the manual is replaced Checklist A Procedures 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition D Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Genie distributor or Genie if replacement manuals or decals are needed Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS
128. he cover Place a drain pan or other suitable container under the hydraulic tank Refer to Specifications Machine Specifications Remove the drain plug from the hydraulic tank and completely drain the tank AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Tag disconnect and plug the suction hose from the hydraulic tank Cap the fitting Loosen the tank strap retaining fastener in front of the tank Move the strap to the side Remove the hydraulic tank from the machine Remove the suction strainer and clean using a mild solvent or replace Clean the inside of the hydraulic tank using a mild solvent Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 39 Service Manual January 2015 Checklist E Procedures 12 13 14 15 16 17 18 19 20 21 22 23 40 Install the drain plug using thread sealer on the threads Install the suction strainer using thread sealer on the threads Install the hydraulic tank onto the machine Secure the tank with the tank strap Do not over tighten Install the suction hose onto the tank Install the return hose onto the tank Fill the tank with hydraulic oil until the fluid is within the top 2 inches 5 cm of the sight gauge Do not overfill Clean up any oil that may have spilled
129. he linkage A WARNING Crushing hazard The linkage assembly assembly could become unbalanced and fall if not Component damage hazard properly supported when Cables and hoses can be removed from the machine damaged if they are kinked or pinched Genie 60 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 eee 13 Remove the retaining fasteners from the number 4 pivot pins Note Do not remove the external snap ring 14 15 16 17 Using a soft metal drift remove the pivot pins and set aside Carefully lift the linkage assembly off of the machine and place it on a structure capable of supporting it Tag and disconnect the harness from the upper lift cylinder valve block Tag and disconnect the hydraulic hoses from the upper lift cylinder Plug the hoses and cap the fittings AWARNING Bodily injury hazard Spraying 18 19 20 21 Part No 214415 hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Remove the cables and hoses from the linkage assembly Component damage hazard Cables and hoses can be damaged if they are kinked or pinched Using a suitable lifting device remove the retaining fasteners from the upper lift cylinder Remove the cylinder Using a suitable supporting device attach a strap to the rod end of the lower lift cylinder Do not ap
130. he tank into a container of suitable capacity Refer to Specifications Machine Specifications AWARNING Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Hydraulic Tank 3 Tag and disconnect the harnesses from the ground control box 4 Remove the ground control box from the machine and set aside 5 Tag disconnect and plug the hydraulic hoses from the hydraulic tank Cap the fittings on the tank 6 Loosen the hydraulic tank mounting strap fastener Pull the tank strap to the side Note Do not remove the tank strap 7 Remove the hydraulic tank from the machine Component damage hazard During installation do not overtighten the hydraulic tank strap mounting fastener Note Clean the hydraulic tank and inspect for cracks or other damage before installing Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 95 Part No 214415 Service Manual January 2015 Steer Axle Components 8 1 Left side yoke Yoke Assembly 7 Remove the retaining fasteners from the tie rod pivot pin How to Remove the Yoke 1 Chock both sides of the wheels at the non steer end of the machine 2 Centera lifting jack under the drive chassis at the steer end of the machine 3 Loosen the wheel lug bolts Do not remove them 4 Raise the machine approximately 2 inc
131. hes 5 cm Place blocks under the chassis for support A WARNING Crushing hazard The chassis Will fall if not properly supported 5 Remove the wheel lug bolts Remove the tire and wheel assembly 6 Support and secure the yoke and assembly with a lifting device 1 upper king pin 2 tie rod pivot pin 3 lower king pin 4 steer sensor assembly 5 yoke assembly 8 Use a small pry bar to move the pivot pin down enough to clear the steer sensor assembly 9 Remove the steer sensor actuator and spring from the tie rod pivot pin and set aside 10 Remove the steer sensor assembly and set it aside 11 Using a soft metal drift pin and a mallet drive the pivot pin up to remove it Lo QGanie 1 1 1 1 96 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 Service Manual January 2015 12 Remove the retaining fastener from the lower yoke king pin 13 Use a small pry bar to remove the king pin 14 Remove the retaining fastener from the upper yoke king pin 15 Use a small pry bar to remove the king pin 16 Remove the yoke assembly from the machine ACAUTION Crushing hazard The assembly may become unbalanced and fall if not properly supported and secured with a suitable lifting device when it is removed from the machine Right side yoke Steer Axle Components How to Remove a Drive Motor Component damage hazard Repairs to the motor should only be performed by an authorized dealer Compon
132. hortcuts may produce hazardous conditions Repair Procedures Machine Configuration MI Unless otherwise specified perform each repair procedure with the machine in the following configuration Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC Machine parked on a firm level surface Key switch in the off position with the key removed The red Emergency Stop button in the off position at both ground and platform controls Wheels chocked All external AC power supply disconnected from the machine Platform in the stowed position 43 Service Manual January 2015 Repair Procedures About This Section Symbols Legend Most of the procedures in this section should only Safety alert symbol used to alert be performed by trained service professional in a personnel to potential personal suitably equipped workshop Select the injury hazards Obey all safety appropriate repair procedure after troubleshooting the problem messages that follow this symbol to avoid possible injury or death Perform disassembly procedures to the point ADANGER Indicates a imminently hazardous where repairs can be completed Then to re assemble perform the disassembly steps in reverse order situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION ndicates a potentially hazardou
133. iation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Genie A TEREX BRAND Genie UK The Maltings Wharf Road Grantham Lincolnshire NG31 6BH England 44 1476 584333 Terex South Dakota Inc USA 500 Oak Wood Road PO Box 1150 Watertown SD 57201 6150 605 882 4000 Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N 7 no remove from service R 7 repaired Comments Pre delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print
134. in each air filled tire Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 25 Part No 214415 Service Manual January 2015 Checklist B Procedures B 5 Test the Emergency Stop Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first A properly functioning Emergency Stop button is essential for safe machine operation An improperly operating red Emergency Stop button will fail to shut off power and stop all machine functions resulting in a hazardous situation As a safety feature selecting and operating the ground controls will override the platform controls except the platform red Emergency Stop button 1 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push in the red Emergency Stop button at the ground controls to the off position Result No machine functions should operate 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Push down the red Emergency Stop button at the platform controls to the off position Result No machine functions should operate Note The red Emergency Stop button at the ground controls will stop all machine operation even if the key is switched to platform control Note If in ground controls mode and the red Emergency Stop bu
135. ine is in the GCON ECM elevated position If machine is in stowed position a functionality is resumed H084 H084 COILFAULT Short circuit of the oscillate supply Short circuit in oscillate supply harness All functions inhibited except platform OSC SUPPLY Bat circuit to battery positive Oscillate supply coil short circuit as long as machine is in the elevated GCON ECM position If machine is in stowed position a functionality is resumed H085 H085 COILFAULT Short circuit of the oscillate right Short circuit in oscillate right harness All functions inhibited except platform OSC RIGHT Bat circuit to battery negative Oscillate right coil short circuit as long as machine is in the elevated GCON ECM position f machine is in stowed position a functionality is resumed H086 H086 COILFAULT Open circuit of the oscillate right Open circuit in oscillate right harness All functions inhibited except platform as OSC RIGHT Open circuit Oscillate right coil open circuit ong as machine is in the elevated GCON ECM position f machine is in stowed position all unctionality is resumed H087 H087 COILFAULT Short circuit of the oscillate right Short circuit in oscillate right harness All functions inhibited except platform as OSC RIGHT Bat circuit to battery positive Oscillate right coil short circuit long as machine is in the elevated GCON ECM position f machine is in stowed position all unctionality is resumed H088 H08
136. inhibited OVERRIDE MODE ON except for down function and up function Platform can be elevated only once with the maximum elevate time of XX seconds Elevate time XX depends on machine model C030 C030 DCON RR ECM Hardware failure of the right rear Right rear DCON ECM Performance reduced or FAULT TYPE 01 drive controller all functions inhibited C031 C031 DCON LR ECM Hardware failure of the left rear drive Left rear DCON ECM Performance reduced or FAULT TYPE 01 controller all functions inhibited C032 C032 DCON RR ECM Setup initialization failure of the right Drive input active at system startup Performance reduced or FAULT TYPE 02 rear drive controller at system Faulty drive joystick drive inhibited or all startup Incorrect software D14 functions inhibited Right rear DCON ECM C033 C033 DCON LR ECM Setup initialization failure of the left Drive input active at system startup Performance reduced or FAULT TYPE 02 rear drive controller at system Faulty drive joystick drive inhibited or all startup Incorrect software D14 functions inhibited Left rear DCON ECM Part No 214415 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 141 Service Manual January 2015 Ts Fault Codes Type CXXX Faults continued DTC Message on Description Possible Causes Failure Mode Number GCON
137. it GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed Genie ATEREX BRAND 130 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Baas EE ER A Type PXXX Faults Fault Codes DTC 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 311 circuit to battery negative digital tilt switch harness GCON ECM P003 P003 PWRFAULT Short circuit of the switched power Short circuit in switched power 1 down limit switch or All functions inhibited SW PWR1 Bat 311 circuit to battery positive digital tilt switch harness GCON ECM P004 P004 DEVICEFAULT Short circuit of the automotive horn Short circuit in automotive horn harness Automotive horn inhibited HORN Bat circuit to battery negative Automotive horn short circuit GCON ECM POOS P005 DEVICEFAULT Open circuit of the automotive horn Open circuit in automotive horn harness Automotive horn inhibited HORN Open circuit Automotive horn open circuit GCON ECM P006 P006 DEVICEFAULT Short circuit of the automotive horn Short circuit in automotive horn harness Automotive horn inhibited HORN
138. itch All GCON LCD menu GCON LCD UP up switch at system startup GCON ECM functions inhibited U005 U005 SWITCHFAULT Short circuit of the GCON LCD scroll Short circuit of the GCON LCD scroll down switch All GCON LCD menu GCON LCD DOWN down switch at system startup GCON ECM functions inhibited U006 U006 SWITCHFAULT Short circuit of the GCON LCD enter Short circuit of the GCON LCD enter switch All GCON LCD menu GCON LCD ENTER switch at system startup GCON ECM functions inhibited U007 U007 SWITCHFAULT Short circuit of the GCON LCD Short circuit of the GCON LCD escape switch All GCON LCD menu GCON LCD ESCAPE escape switch at system startup GCON ECM functions inhibited U014 U014 SWITCHFAULT Short circuit of the PCON drive Short circuit of the PCON drive enable switch All PCON drive and steer PCON DRIVE EN enable switch at system startup GCON ECM functions inhibited U015 U015 SWITCHFAULT Short circuit of the PCON steer left Short circuit of the PCON steer left switch All PCON drive and steer PCON STEER LEFT switch at system startup GCON ECM functions inhibited U016 U016 SWITCHFAULT Short circuit of the PCON steer right Short circuit of the PCON steer right switch All PCON drive and steer PCON STEER RIGHT switch at system startup GCON ECM functions inhibited U017 U017 SWITCHFAULT Short circuit of the PCON horn Short circuit of the PCON horn switch PCON horn switch PCON HORN switch at system startup
139. itch shorted battery positive unctions inhibited positive PCON ECM U039 U039 SWITCHFAULT Open or short circuit of the PCON Open or short circuit in PCON power harness All drive and steer FOOTSW Open Bat power circuit to enable switch to Enable switch short or open to battery negative unctions inhibited battery negative PCON ECM U040 U040 SWITCHFAULT Enable switch held closed with no Enable switch held closed All drive and steer FOOTSW Timeout activity Enable switch contact stuck closed unctions inhibited PCON ECM U041 U041 SWITCHFAULT PCON lift mode switch stuck closed Lift mode switch stuck closed Lift function inhibited PCON LIFT MODE or depressed prior to startup Lift mode switch is depressed at system startup PCON ECM U042 U042 SWITCHFAULT PCON drive mode switch stuck Drive mode switch stuck closed Drive function inhibited PCON DRIVE MODE closed or depressed prior to Drive mode switch is depressed at system startup startup PCON ECM U043 U043 SWITCHFAULT PCON outrigger mode switch stuck Outrigger mode switch stuck closed Outrigger extend retract PCON OR MODE closed or depressed prior to Outrigger mode switch is depressed at system startup function inhibited startup PCON ECM U045 U045 SWITCHFAULT Short circuit of the PCON drive Short circuit of the PCON drive enable switch All drive and steer PCON DRIVE EN enable switch at system startup PCON ECM functions inhibited GCON ECM
140. ive motor encoder All functions inhibited ENCODER FAULT motor encoder to the left rear drive Faulty encoder in left rear drive motor controller is 40 Hz or higher Faulty left rear drive motor Left rear DCON ECM F059 F059 MOTOR RR Right rear drive motors rotor is stuck Right rear drive motor not turning Drive functions inhibited STALL ENCODER or the return signal from the encoder Short or open of the drive motor encoder is incorrect Faulty encoder in right rear drive motor Faulty right rear drive motor Right rear DCON ECM F060 F060 MOTOR LR Left rear drive motors rotor is stuck Left rear drive motor not turning Drive functions inhibited STALL ENCODER or the return signal from the encoder Short or open of the drive motor encoder is incorrect Faulty encoder in left rear drive motor Faulty left rear drive motor Left rear DCON ECM F061 F061 MOTOR RR Open circuit of the right rear drive Open circuit in right rear drive motor harness Drive performance THERMAL SENSOR motor thermal sensor to right rear Faulty thermal sensor in right rear drive motor reduced drive controller D3 or faulty thermal Right rear DCON ECM sensor F062 F062 MOTOR LR Open circuit of the left rear drive Open circuit in left rear drive motor harness Drive performance THERMAL SENSOR motor thermal sensor to left rear Faulty thermal sensor in left rear drive motor reduced drive controller D3 or faulty thermal Left rear
141. klist D Procedures D 3 Replace the Drive Hub Oil Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Replacing the drive hub oil is essential for good machine performance and service life Failure to replace the drive hub oil at yearly intervals may cause the machine to perform poorly and continued use may result in component damage 1 Select the drive hub to be serviced Drive the machine until one of the two plugs is at the lowest point 2 Remove the plugs and drain the oil into a suitable container 3 Drive the machine until one of the two plugs is at the highest point 1 drive hub plugs 4 Fillthe hub until the oil level is even with the bottom of the lowest plug hole Refer to Specifications Machine Specifications 5 Install the plugs into the drive hub Repeat this procedure for each drive hub Part No 214415 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 37 Service Manual January 2015 Checklist D Procedures D 4 Test the Function Pump Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Proper use of the free wheel configuration is essential to safe machine operation The free wheel configuration is used primarily for towing A machine configured to free wheel without operator knowledge may cause death or serious injury and property damage Proper
142. kwise 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 Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tighten the joint after it has been loosened Illustration 2 a_ body hex fitting b reference mark c second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body hex fitting 5 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 9 Service Manual January 2015 Specifications SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength THREAD Grades C Grade8 C LUBED DRY LUBED DRY in Ibs Nm in Ibs Nm in Ibs Nm in Ibs Nm 44 L2 so 9 10 113 110 124 140 158 130 147 28 9 0 1 120 135 1 120 1 135 1 160 18 1 140 158 1 EK o eoem DRY LUBED DRY LUBED ft lbs Nm ftibs_ Nm fttbs Nm ftibs Nm tts _ Nm sig 18 13 176 17 23 18 24 25 339 21 284 24 14 19 19 257
143. le 3 Disconnect the connector with the green wire from the oscillate left coil item 1 and swap it with the connector with the blue black wire from the steer left coil item 4 Lo Qai 1 1 1 100 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Steer Axle Components 8 6 7 Remove the tie rod pivot pin retaining SteerAngleSensor fees 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 The control system uses the steer angle input along with pre programmed parameters to vary the speed of each drive motor while steering to minimize tire scrub and to help minimize turning radius Drive speed is also reduced proportionately depending on the steer angle to minimize lateral platform acceleration 1 Adjust the steer tires so they are in a straight driving position 2 Turn the key switch to the off position Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off steer sensor cover 1 2 position 3 compression spring 4 5 left yoke assembly steer sensor actuator tie rod pivot pin 4 Remove the cable clamp securing the steer sensor cable to the chassis 5 Tag and disconnect the steer sensor harness 8 Use a small pry bar to move the pivot pin from the main harness down enough to clear the steer s
144. lease enable harness All functions inhibited BRAKE REL Bat Brake release relay open circuit GCON ECM except platform down H045 H045 COILFAULT BRAKE REL Bat Short circuit of the brake circuit to battery positive Short circuit in brake release enable harness Brake release relay short circuit GCON ECM All functions inhibited except platform down H049 H049 COILFAULT O R EXTEND Bat H050 H050 COIL FAULT O R EXTEND Open Short circuit of the outrigger extend coil to battery negative Open circuit in the outrigger extend coil circuit Short circuit in outrigger extend coil harness Outrigger extend coil short circuit GCON ECM Open circuit in outrigger extend coil harness Outrigger extend coil open circuit GCON ECM Only outrigger extend function disabled Only outrigger extend function disabled H051 H051 COILFAULT O R EXTEND Bat Short circuit of the outrigger extend Coil to battery positive Short circuit in outrigger extend coil harness Outrigger extend coil short circuit GCON ECM All functions inhibited except platform down H052 H052 COILFAULT O R RETRACT Bat Short circuit of the outrigger retract coil to battery negative Short circuit in outrigger retract coil harness Outrigger retract coil short circuit GCON ECM Only outrigger retract function disabled H053 H053 COILFAULT O R RET Open
145. leshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M V Immediately tag and remove from service a V Repair any machine damage or malfunction before operating the machine M Unless otherwise specified perform each procedure with the machine in the following Fault Codes Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Read each appropriate fault code thoroughly Attempting short cuts may produce hazardous conditions Be aware of the following hazards and follow generally accepted safe workshop practices damaged or malfunctioning machine ADANGER Crushing hazard When testing or replacing any hydraulic component always support the structure and secure it from movement configuration AWARNING Electrocution burn hazard e Machine parked on a firm level surface e Key switch in the off position with the key removed Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry e The red Emergency Stop button in the off AWARNING Bodily injury hazard Spraying position at both ground and platform controls e Wheels chocked All external AC power supply disconnected from the machine e Platfo
146. librated Note After installing a new outrigger level sensor the new outrigger level sensor must be calibrated following this procedure Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 111 Service Manual January 2015 i its Platform Overload Components 11 1 Platform Overload System if equipped How to Calibrate the Platform Overload System if equipped Machines with platform overload systems proper calibration is essential to safe machine operation An improperly calibrated platform overload system could result in the system failing to sense an overloaded platform The stability of the machine is compromised and it could tip over Note For troubleshooting information refer to Repair Procedure Troubleshooting the Platform Overload System 1 Models with outriggers Deploy the outriggers and level the machine 2 Apply a thin layer of dry film lubricant to the area of the chassis where the scissor arm wear pads make contact 3 Using a suitable lifting device place and secure the maximum rated load in the center of the platform deck 4 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 5 Raise the platform approximately 10 feet 3m 6 Lower the platform until the down limit switch activates and the platform stops lowering 7 Locate a supporting device under the platform Do
147. linder Note After an outrigger cylinder has been install the machine must be re calibrated Refer to Repair Procedure Outrigger Calibration Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 109 Part No 214415 Service Manual January 2015 Outrigger Components 10 2 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 The ECM is also used to calibrate the outrigger level sensor to achieve a levelness of 0 0 5 front to back and side to side while the outriggers are deployed For further information or assistance consult the Genie Product Support How to Calibrate the Outrigger System Move the machine to an area that has a firm level surface and is free of obstructions 1 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls 2 Press and hold the ground control scroll up and scroll down buttons scroll down button enter button scroll up button escape button LCD display ak WN 3 Pull out the red Emergency Stop button to the on position at the ground controls Result The ground controls LCD display will show the following
148. linder rod end pivot pin Number 3 inner arm Number 3 pivot pin steer end Number 2 center pivot pin Qty Number 2 pivot pin steer end Number 1 center pivot pin Qty ANSI CSA OR Number 1 center pivot pin Qty AS CE Number 1 inner arm Chassis pivot Genie ATEREX BRAND 17 18 19 20 21 23 24 25 26 27 28 29 30 GS 2669 DC GS 3369 DC GS 4069 DC Non steer End Slider block Qty 2 Number 5 inner arm Number 5 outer arm Number 5 pivot pin non steer end Upper lift cylinder rod end pivot pin Number 4 outer arm Number 4 pivot pin non steer end Upper lift cylinder barrel end pivot pin Number 3 outer arm Number 3 pivot pin non steer end Number 2 inner arm Number 2 outer arm Number 2 pivot pin non steer end Lower lift cylinder barrel end pivot pin Number 1 outer arm 59 Service Manual January 2015 Scissor Components 3 3 Scissor Assembly GS 4069 DC How to Disassemble the Scissor Assembly AWARNING Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during
149. long as negative GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed F047 F047 SWITCHFAULT Short circuit of the right axle Short circuit of the right axle operational limit switch All functions inhibited RIGHT AXLE Bat operational limit switch to battery Short circuit in axle limit switch harness except platform as long as positive GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed Part No 214415 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 137 Service Manual January 2015 Ts Fault Codes Type FXXX Faults continued DTC Message on Description Possible Causes Failure Mode Number GCON LCD F048 F048 SWITCHFAULT Short circuit of the right axle Short circuit of the right axle operational limit switch All functions inhibited RIGHT AXLE BAT operational limit switch to Short circuit in axle limit switch harness except platform down as batterynegative GCON ECM long as machine is in the elevated position If machine is in stowed position all functionality is resumed 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 Short circuit in pump speed sensor harness GCON ECM F050 F050 SENSORFAULT Short circuit of the pump
150. ltimeter to the positive terminal on the 9V DC battery Note and record the current reading 6 Atthe battery or coil terminals reverse the connections Note and record the current reading Result Both current readings are greater than 0 mA and are different by a minimum of 20 The coil is good Result If one or both of the current readings are 0 mA or if the two current readings do not differ by a minimum of 20 the coil and or its internal diode are faulty and the coil should be replaced Genie 94 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 7 1 Hydraulic Tank The primary functions of the hydraulic tank is to cool clean and deaerate the hydraulic fluid during operation It utilizes internal suction strainer for the pump supply line How to Remove the Hydraulic Tank Component damage hazard The work area and surfaces where this procedure will be performed must be clean and free of debris that could get into the hydraulic system and cause severe component damage Dealer service is recommended Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the hydraulic tank cap 2 Remove the drain plug from the hydraulic tank and completely drain t
151. lug always GLOWPLUG B to battery negative Faulty CR15 relay activated Faulty motor controller harness Right rear DCON ECM P052 P052 PWR FAULT Short or open circuit of the glow plug Faulty glow plug Engine may not start at GLOWPLUG Open Bat circuit to battery positive Faulty fuse F33 cold temperatures Faulty motor controller harness Right rear DCON ECM Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 133 Service Manual A a Fault Codes Type UXXX Faults January 2015 DTC 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 GCON ECM inhibited startup U002 U002 SWITCHFAULT Short circuit of the GCON up Short circuit of the GCON up directional switch All GCON functions GCON PLAT UP directional switch at system startup GCON ECM inhibited except platform up U003 U003 SWITCHFAULT Short circuit of the GCON down Short circuit of the GCON down directional switch All GCON functions GCON PLAT DOWN directional switch at system startup GCON ECM inhibited except platform down U004 U004 SWITCHFAULT Short circuit of the GCON LCD scroll Short circuit of the GCON LCD scroll up sw
152. lve 3 platform up valve Genie 82 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Manifolds How to Adjust the Oscillate Relief 10 Remove the pressure gauge Valve Note Perform this procedure with the machine in the stowed position and in high torque mode 1 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to test port 2 TP2 on the function manifold Disconnect the harness from the oscillate supply coil and the steer right coil Connect the oscillate supply harness to the steer right coil and the steer right harness to the oscillate supply coil Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Steer the machine to the right and hold Note the pressure readings on the pressure gauge Refer to Specifications Hydraulic Components Specifications Use a wrench to hold the oscillate relief valve and remove the cap Adjust the internal hex socket Turn it 1 test port 2 clockwise to increase the pressure or 2 oscillate supply coil green white and counterclockwise to decrease the pressure brown wires Install the relief valve cap Co steer right coil blue and brown wires AWARNING Tip over hazard Do not adjust 4 oscillate relief valve the relief valve higher than specified Repeat this procedure beginning with step 5 to confirm the relief valve press
153. mbly off of the machine and place it on a structure capable of Separate the link sets supporting it 1 Using an overhead lifting device attach a 4 hook sling chain to the ends of the inner 32 Tag and disconnect the harness from the arm Make the chains tight but do not apply lower lift cylinder valve block lifting pressure 33 Tag and disconnect the hydraulic hoses from Crushing hazard The linkage the lower lift cylinder Plug the hoses and cap AWARNING assembly could become the fittings unbalanced and fall if not TENE properly supported when AWARNING Bodily injury hazard Spraying removed from the machine hydraulic oil can penetrate and bum skiti oase hydraulic 2 Remove the retaining fasteners from the connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 34 Remove the hose clamps and hoses from the number 1 inner arm 4 35 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 1 inner arm Make the chains tight but do not apply lifting pressure AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine 36 Remove the two carriage bolts that secure the inner arm and chassis pivot to the steer end of the drive chassis 37 Move the linkage towards the non steer end of the machine until the slider feet are clear of the slider channel 38 Carefully lift th
154. mperage increases As resistance rises above specification voltage increases While valves may operate when coil resistance is outside specification maintaining coils within specification will help ensure proper valve function over a wide range of operating temperatures Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Note If the machine has been in operation allow the coil to cool at least 3 hours before performing this test 1 Tag and disconnect the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance Q Refer to the Valve Coil Resistance Specification table Result If the resistance is not within the adjusted specification plus or minus 10 replace the coil Manifolds Valve Coil Resistance Specification Note The following coil resistance specifications are at an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature the coil resistance will typically increase or decrease by 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Description Specification Solenoid valve 2 position 2 way 250 24V DC with diode schematic items CA CB CC CD CE CF Solenoid valve 2 position 3 way 350 24V DC with diode schematic items BA FB FF FO FP FR
155. nd may cause component damage 1 Open the hydraulic compartment 2 Open the contactor box below the ground control box 3 Visually inspect the contact points of the contactor for the following items e Excessive burns e Excessive arcs e Excessive pitting AWARNING Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Note Replace the contactor if any damage is found Genie 30 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual B 13 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and a clogged suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often For hydraulic oil specifications refer to Specifications Hydraulic Specifications Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Refer to Main
156. nd controls harness connections motor controllers battery charger Gri 24 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual B 4 Inspect the Tires Wheels and Castle Nut Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels including proper wheel fastener torque is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING Bodily injury hazard An over inflated tire can explode and could cause death or serious injury AWARNING Tip over hazard Do not use temporary flat tire repair products Note The tires on some machines are foam filled and do not need air added to them 1 Check tire surface and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracks Checklist B Procedures 3 Remove the castle nut cotter pin and check each castle nut for proper torque Refer to Maintenance Procedure Grease the Steer Axle and Wheel Bearings Note Always replace the cotter pin with a new one when removing the castle nut or when checking the torque of the castle nut 4 Check each lug nut for proper torque Refer to Specifications Machine Specifications 5 Check the pressure
157. nditions may require that the cap be inspected 1 9 to 2 1 m more often 1 Remove and discard the hydraulic tank breather cap 2 Install new cap onto the tank Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 35 Service Manual January 2015 Checklist D Procedures D 1 Check Scissor Arm Wear Pads and Slider Blocks Genie specifications require that this procedure be performed every 1000 hours or annually whichever comes first Maintaining the condition of the scissor arm wear pads is essential to safe machine operation Continued use of worn out wear pads may result in component damage and unsafe operating conditions 1 Measure the thickness of each platform scissor arm slider blocks at the non steer end of the machine Result The measurement is 3 875 inch 9 843 cm or more Proceed to step 2 Y Result The measurement is less than 3 875 inch 9 843 cm Replace both slider blocks 2 Measure the thickness of each chassis scissor arm upper and lower slider wear pads at the non steer end of the machine Result The measurement is 1 4 inch 6 35 mm or more Proceed to step 3 D Result The measurement is less than 11 32 inch 8 71 mm Replace both upper and lower slider wear pads D 2 Replace the Hydraulic Filter Genie requires that this procedure be performed every 1000 hours or annually whichever comes first Replacement of the hydraulic tank return filter is ess
158. ne or motor e NO di CN COM N C Needle valve HE TAI Solenoid operated 3 position 4 way directional valve ET Solenoid operated 3 position 5 way directional valve Pressure switch A n Solenoid operated 2 position 3 way directional valve E Solenoid operated 2 position 2 way directional valve Filter with bypass relief Relief valve with pressure D Solenoid operated Differential sensing valve Pilot operated flow regulator valve Dual piloted relief valve valve setting proportional valve e ut L 4 3000 ps 4 i Pod mE 206 8 oa N AE uc Y l 1 A 1 L amp 1 KENES EI TOE Avi X L i I nas AN s l GE saad D EF Counterbalance valve with pressure and pilot ratio Priority flow regulator Part No 214415 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 149 Service Manual January 2015 Limit Switch Legend al 150 ET d EE Sp d left rear outrigger limit switch LS14 left axle oscillate limit switches LSA10S and LSA10SS right rear outrigger limit switch LS15 right axle oscillate limit switches LS
159. o the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display an adjusted specific gravity of 1 277 or higher The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity of 1 217 or below Proceed to step 8 Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 21 Service Manual ee ss Checklist B Procedures 22 Perform an equalizing charge OR fully charge 10 the battery s and allow the battery s to rest at least 6 hours Remove the battery vent caps and check the specific gravity of each battery cell with a hydrometer Note the results 11 Check the ambient air temperature and adjust the specific gravity reading for each cell as follows e Add 0 004 to the reading of each cell for every 10 5 5 C above 80 F 26 7 C e Subtract 0 004 from the reading of each cell for every 10 5 5 C below 80 F 26 7 C Result All battery cells display a specific gravity of 1 277 or greater The battery is fully charged Proceed to step 11 Result One or more battery cells display a specific gravity from 1 218 to 1 269 The battery is still usable but at a lower performance The battery will need to be recharged more often Proceed to step 11 Result One or more battery cells display a specific gravity from
160. oad in platform GS 2669 DC Platform up 29 to 39 seconds Platform down 26 to 36 seconds GS 3369 DC Platform up 34 to 44 seconds Platform down 24 to 34 seconds GS 4069 DC Platform up 56 to 66 seconds Platform down 23 to 33 seconds Outrigger leveling maximum Front 5 3 Back 4 2 Side to side 11 7 Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Hydraulic Specifications Hydraulic Fluid Specifications Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation prevention corrosion inhibition seal conditioning and foam and aeration suppression properties Cleanliness level ISO 15 13 minimum Water content 250 ppm maximum Recommended Hydraulic Fluid Hydraulic oil type Chevron Rando HD Premium Viscosity grade 32 Viscosity index 200 Optional Hydraulic Fluids Shell Tellus S2 V 32 Shell Tellus S2 V 46 Chevron 5606A Petro Canada Environ MV 46 UCON Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved opti
161. oe AMA 45 V2PBD RD BK yo Ace Ue aba vol E is l PLATFORM E amp 5 ye vio ARE 21 V52APV BURD LSA1OS N63 7 oe LSA2OS uL H gt 1 3 Ze A GND BR LEFT med ANG cd NC RIGHT l S8 ANALOG F30 10A ME cmt 0 LEVEL UE i Rr RO BLY cao l SENSOR Sne 9 onic US C276 rn e5 z I RIG BATTERY 24V Fa 6 LC BALANCER 448V ene ee WHO BAMHI 35 C134PWR RD S l F29 104 ut Giani 2 ES l 24V si 134LO RD A SE a o EE EN ENE IG ien NOTES DOTTED LINES REPRESENT OPTIONS H I d ees ES0539E I Genie A TEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 eee SE Sz Service Manual Electrical Schematic GS 4069 DC ANSI CSA
162. ols and terminates at system ground GCON Electronic Control Module Signal Signal Return Return ECM Wire Side Device Side Wire vl HAL In order to successfully troubleshoot HXXX or PXXX type faults the entire faulted out circuit must be investigated Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 125 Service Manual January 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 27 20 Solenoid Valve Steer 190 Solenoid Valve Platform Up 250 Solenoid Valve Platform Down 6 250 GCON and PCON Alarm 21M O Automotive Horn 1 00 Contactor Coil 470 Replace faulted device Check the harness between the ground controls and the faulted device Disconnect the GCON ECM connectors C1 C2 and C3 or C4 if equipped with outriggers Disconnect the faulted device connector Check the continuity between the GCON ECM connector and the signal side of the faulted device Result Resistance should be close to 0 Q Check the continuity between the return side of faulted device and system ground Result Resistance should be close to 0 Q Check resistance bet
163. onal fluids Consult Genie Product Support before use Mineral based Biodegradable Fire resistant Optional fluids may not have the same hydraulic lifespan and may result in component damage Note Extended machine operation can cause the hydraulic fluid temperature to increase beyond it s maximum allowable range If the hydraulic fluid temperature consistently exceeds 200 F 90 C an optional oil cooler may be required Specifications Do not top off with incompatible hydraulic fluids Hydraulic fluids may be incompatible due to the differences in base additive chemistry When incompatible fluids are mixed insoluble materials may form and deposit in the hydraulic system plugging hydraulic lines filters control valves and may result in component damage Note Do not operate the machine when the ambient air temperature is consistently above 120 F 49 C Hydraulic Fluid Temperature Range 40 22 4 14 32 50 68 86 104 122 F 40 30 20 10 O 10 20 30 40 50 C Ambient air temperature 1 Chevron hydraulic oil 5606A 2 Petro Canada Environ MV 46 3 UCON Hydrolube HP 5046D 4 Chevron Rando HD premium oil MV Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 3 Part No 214415 Service Manual January 2015 Specifications Chevron Rando HD Premium Oil MV Fluid Properties ISO Grade 32
164. ontinued DTC Message on Description Possible Causes Failure Mode Number GCON LCD PO46 PO46 PWR FAULT Short to battery positive or open Short or open in engine harness Engine will not start and START Open Bat circuit of the engine start circuit Left rear DCON ECM run with open circuit GCON ECM Engine will not start and run with short to B P047 P047 CHRGR FAULT Short circuit of the primary battery Faulty primary charger Batteries will not charge MAIN Bat charger circuit to battery negative Short in motor controller harness correctly in generator Faulty let DCON ECM mode P048 P048 CHRGR FAULT Short or open circuit of the primary Faulty primary charger Batteries will not charge MAIN Open Bat battery charger to battery positive Short in motor controller harness correctly in generator Faulty left DCON ECM mode P049 P049 CHRGR FAULT Short circuit of the boost battery Faulty boost charger Batteries will not charge Boost Bat charger circuit to battery negative Faulty motor controller harness correctly in generator Faulty right DCON ECM mode P050 P050 CHRGR FAULT Short or open circuit of the boost Faulty boost charger Batteries will not charge Boost Open Bat battery charger to battery positive Faulty motor controller harness correctly in generator Faulty right DCON ECM mode P051 P051 PWR FAULT Short circuit of the glow plug circuit Faulty glow plug Glow p
165. ontroller 185 F 85 C to 221 F has exceeded 185 F 85 C Left rear DCON ECM 105 C Drive inhibited at 221 F 105 C F055 F055 MOTOR RR Right rear drive controller thermal Excessive heat Drive functions inhibited THERM PROTECTION protection senses that temperature Short or open circuit of the drive motor encoder has exceeded 185 F 85 C Faulty thermal sensor in right rear drive controller Right rear DCON ECM FO56 F056 MOTOR LR Left rear drive controller thermal Excessive heat Drive functions inhibited THERM PROTECTION protection senses that temperature Short or open circuit of the drive motor encoder has exceeded 185 F 85 C Faulty thermal sensor in left rear drive controller Left rear DCON ECM 138 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Fault Codes Type FXXX Faults continued DTC Message on Description Possible Causes Failure Mode Number GCON LCD F057 F057 MOTOR RR Return signal from the right rear Short or open circuit of the drive motor encoder All functions inhibited ENCODER FAULT drive motor encoder to the right rear Faulty encoder in right rear drive motor drive controller is 40 Hz or higher Faulty right rear drive motor Right rear DCON ECM F058 F058 MOTOR LR Return signal from the left rear drive Short or open circuit of the dr
166. osition and pull out the red Emergency Stop button to the on position at the platform controls Genie ATEREX BRAND Ground Controls Press and hold the ground control scroll up and scroll down buttons Ground Control Menu Buttons 1 scroll down button 2 enter button 3 scroll up button 4 escape button 5 LCD display Pull out the red Emergency Stop button to the on position at the ground controls Result The ground controls LCD display will show the following LIFT SETUP TEST SELECT MODEL EI Use the ground control menu buttons to select machine Model Options and Speed Setup parameters Follow the menu structure indicated on the ground control LCD display Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 69 Service Manual January 2015 Ground Controls 4 3 Auxiliary Platform Lowering In the event of a main power failure activating the auxiliary enable and auxiliary platform lowering toggle switches at the ground controls will lower the platform There is no adjustment required 4 4 Level Sensor Models without 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 The tilt alarm sounds when the incline of the chassis exceeds 2 to the side and 3 to
167. ove the Platform Controls Alarm 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Disconnect the platform controls from the control cable at the platform 3 Remove the fasteners securing the platform control box to the platform control bracket 4 Remove the fasteners securing the bottom cover to the platform control box Open the control box 5 Disconnect the red and black wires from the alarm Electrocution burn hazard A WARNING Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Component damage hazard Electrostatic discharge ESD can damage printed circuit board components Maintain firm contact with a metal part of the machine that is grounded at all times when handling printed circuit boards OR use a grounded wrist strap 6 Carefully remove the alarm from the platform control box 1 4 Platform Emergency Stop Button How to Remove the Platform Controls Emergency Stop Button 1 Pushin the red Emergency Stop button to the off position at both the ground and platform controls 2 Disconnect the platform controls from the control cable at the platform 3 Remove the fasteners securing the platform control box to the platform control bracket 4 Remove the fasteners securing the bottom cover to the platform control box Open the control box 5 Disconnect the white wires
168. performed every 250 hours or quarterly whichever comes first A functioning horn is essential to safe machine operation The horn is activated at the platform controls and sounds at the ground as a warning to ground personnel An improperly functioning horn will prevent the operator from alerting ground personnel of hazards or unsafe conditions 1 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Push down the horn button at the platform controls Result The horn should sound Note If necessary the horn can be adjusted to obtain the loudest volume by turning the adjustment screw near the wire terminals on the horn Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 27 Part No 214415 Service Manual January 2015 Checklist B Procedures B 8 Test the Drive Brakes Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper brake action is essential to safe machine operation The drive brake function should operate smoothly free of hesitation and unusual noise Electrically released individual wheel brakes can appear to operate normally when not fully operational Note Perform this procedure with the machine on incline button at the platform controls in the off position LED light should be off and the platform extension deck fully ret
169. play will show the following LIFT SETUP TEST 1 SELECT OPTION EI Press the enter button Result The ground control LCD display will show the following SELECT OPTION PLAT OVERLOAD Press the enter button Result The ground control LCD display will show the following PLAT OVERLOAD ENABLE DI Part No 214415 January 2015 Service Manual Platform Overload Components 7 Press and hold the scroll down button for 5 seconds Result The ground control LCD display will show the following RESET OVLD RECOVERY DI 8 Press the enter button Result The ground control LCD display will show the following INPUT PASSWORD k 9 Press the buttons in the following sequence down down up enter Note After each key press an asterisk will appear on the second line of the LCD display O Result The ground control LCD display will show the following OVLD RECOVERY RESET Note After 3 seconds the LCD display will return to SELECT OPTION PLAT OVERLOAD 10 Pushin the red Emergency stop button Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 117 Service Manual January 2015 A esese e ee This page intentionally left blank Gri 118 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual EN v Observe and Obey E V Troub
170. ply pressure Remove the lower cylinder rod end pivot pin retaining fasteners Service Manual Scissor Components 22 Using a soft metal drift remove the pivot pin 23 Lower the lift cylinder and remove the strap 24 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 3 inner arm Make the chains tight but do not apply lifting pressure AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine 25 Remove the retaining fasteners from the number 3 pivot pins Note Do not remove the external snap ring 26 Using a soft metal drift remove the pivot pins and set aside 27 Carefully lift the linkage assembly off of the machine and place it on a structure capable of supporting it 28 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 2 inner arm Make the chains tight but do not apply lifting pressure AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine 29 Remove the retaining fasteners from the number 2 pivot pins Note Do not remove the external snap ring 30 Using a soft metal drift remove the pivot pins and set aside Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 61 Service Manual January 2015 Scissor Components 31 Carefully lift the linkage asse
171. pporting it Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 57 Service Manual January 2015 se He Scissor Components Separate the link sets 1 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 AWARNING Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine 2 Remove the retaining fasteners from the center pivot pins Note Do not remove the external snap ring 3 Using a soft metal drift remove the center pivot pins and set aside 4 Carefully lift and separate the linkage assembly apart and place it on a structure capable of supporting it Lo Qai 1 1 amp 58 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Scissor Components OLOJO Ii SET e E N o 21 0 2 26 OOOO 1980 a oO Oo Joo bk h A as O EY ox w N 14 15 Part No 214415 Q Steer End Platform pivot Number 5 center pivot pin Qty Number 5 pivot pin steer end Number 4 center pivot pin Qty Number 4 inner arm Number 4 pivot pin steer end Number 3 center pivot pin Qty GS 4069 2 Lower lift cy
172. pressure Install the relief valve cap 32 33 35 36 37 38 39 40 ADANGER Tip over hazard Failure to adjust the relief valves to specification could result in the 42 machine tipping over causing death or serious injury Do not adjust the relief valve pressures higher than specifications 28 Repeat this procedure beginning with step 24 to confirm the relief valve pressure 29 Lower the platform to the stowed position 30 Remove the weight from the platform 43 31 Raise the platform approximately 10 feet 3 m Genie 88 GS 2669 DC GS 3369 DC GS 4069 DC Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position Lower the platform onto the safety arm Push in the red Emergency Stop button to the off position Connect the harness to the lift cylinder pressure switch Release the maximum height limit switch roller head and connect the harness Pull out the red Emergency Stop button to the on position and raise the platform approximately 10 feet 3 m Return the safety arm to the stowed position Lower the platform to the stowed position Push in the red Emergency Stop button to the off position Press and hold the ground control scroll up and scroll down buttons Pull out the red Emergency Stop button to the on position at the ground controls Result The ground controls LCD display will show the following LIFT SETUP TEST SELECT M
173. pump function is essential to safe oscillate operation and machine function Note Perform this procedure on a firm level surface with the platform in the stowed position and the platform extension deck fully retracted 1 Lower the platform to the stowed position 2 Turn the key switch to ground control and pull out the red Emergency Stop button to the on position at both ground and platform controls 3 Atthe ground controls record the time it takes to fully raise the platform 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 GS 2669 55 seconds GS 3369 60 seconds GS 4069 94 seconds D Result The time to fully elevate the platform is greater than the table shown above refer to Repair Procedure How to Setup the Machine from Ground Controls Repeat the above procedure Note If the above times can not be achieved the machine must be tagged and removed from service until the function pump is repaired or replaced ADANGER Tip over hazard Failure to repair or replace the function pump as instructed could compromise the stability of the machine resulting in death or serious injury Genie 38 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 Service Manual January 2015 E 1 1 Test or Replace the Hydraulic Oil 2 3 Genie specifications require that this procedure be performed every 2000 hours or every two ye
174. r end of the machine Note The overhead lifting device and strap must be capable of supporting 5000 Ibs 2268 kg Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported AWARNING RI A if 4 Raise the linkage assembly slightly with the overhead lifting device just enough to take pressure off of the slider feet Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 63 Part No 214415 Service Manual January 2015 Scissor Components 5 Remove the retaining fasteners from the slider 9 feet pivot pins and set aside 1 Slider foot assembly 2 pivot pin 3 retaining fasteners 6 Using a soft metal drift remove the pivot pins 10 and set aside 7 Remove the slider feet by sliding them out of the slider channel 11 8 Remove the upper and lower wear pads and discard 12 Genie 64 GS 2669 DC GS 3369 DC GS 4069 DC Using a hard rubber mallet secure the upper and lower wear pads to the slider feet ET 1 upper wear pads 2 slider foot 3 lower wear pad Install the slider feet into the slider channel and secure them to the linkage assembly with the pivot pins Securely tighten the pivot pin retaining fasteners Securely install the ladder onto the machine Do not over tighten the fasteners Part No 214415 January 2015 Service Manual Scissor Components 3 5 Lift Cylinde
175. racted 1 Mark a test line on the ground for reference 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Press the drive function select button 4 Press and hold the function enable switch on the joystick 5 Choose a point on the machine Le contact patch of a tire as a visual reference for use when crossing the test line 6 Bring the machine to top drive speed before reaching the test line Release the function enable switch or the joystick when your reference point on the machine crosses the test line Measure the distance between the test line and your machine reference point Refer to Specifications Performance Specifications Note The brakes must be able to hold the machine on any slope it is able to climb Genie 28 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual B 9 Test the Drive Speed Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range 1 Create start and finish lines by marking two lines on the ground 40 fee
176. rcuit No LED 24V lead not connected Disconnected Auto shutdown Red Steady 1 Voltage differential 8V between battery packs OR 2 48V disconnected Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 23 Service Manual January 2015 Checklist B Procedures B 3 e Battery box Inspect the Electrical Wiring batteries fuse box e Machine center of drive chassis Genie specifications require that this procedure be linkage assembly performed every 250 hours or quarterly whichever e platform comes first platform controls Maintaining electrical wiring in good condition is harness connections essential to safe operation and good machine 3 Inspect for a liberal coating of dielectric performance Failure to find and replace burnt grease in all wire harness connectors chafed corroded or pinched wires could result in unsafe operating conditions and may cause e Ground controls component damage e Platform controls AWARNING Electrocution burn hazard e Function manifold Contact with electrically charged circuits could result in e Motor controllers death or serious injury Remove e Limit switches all rings watches and other jewelry e Level sensor 1 Inspect the underside of the chassis for CU damaged or missing ground strap s 2 Inspect the following areas for burnt chafed corroded pinched and loose wires e n the rear axle drive motors limit switches e Hydraulic box inside grou
177. rm in the stowed position Genie ATEREX BRAND hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 119 Service Manual January 2015 Fault Codes About This Section When a malfunction is discovered the fault code charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges General Repair Process Malfunction Identify up Troubleshoot discovered symptoms problem still exists Return to Perform service repair problem solved Definitions GSDS Genie SmartLink Diagnostic System ECM Electronic Control Module DCON Drive Controller GCON Ground Controls PCON Platform Controls OIC Operational Indicator Codes DTC Diagnostic Trouble Codes GCON LCD Diagnostic Readout HOO1 COILFAULT PLAT UP1 Bat The diagnostic readout displays alpha numeric codes that provide information about the machine operating status and about malfunctions The cod
178. rness to the level sensor machine 7 Adjust the level sensor retaining fasteners until the bubble in the top of the level sensor is centered in the circles 5 Install the new level sensor onto the machine with the X on the level sensor base towards the steer end of the machine Install and tighten the level sensor retaining fasteners Note Be sure there are threads showing through the top of the adjusting fasteners ADANGER Tip over hazard The tilt level sensor must be installed with the 8 Turn the key switch to ground control and pull X on the level sensor base out the red Emergency Stop button to the on towards the steer end of the position at both ground and platform controls machine Failure to install the tilt level sensor as instructed could result in the machine tipping over causing death or serious injury Result The tilt sensor alarm should not sound Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 71 Service Manual OO ss Ground Controls 10 11 12 13 14 15 16 17 18 19 20 72 Center a lifting jack under the drive chassis at 21 the ground controls side of the machine Raise the machine approximately 4 inches 10 cm 22 Place a 1 94 x 10 x 10 inch 4 93 x 25 x 23 25 cm thick steel block under both wheels at the ground controls side of the machine Lower the machine onto the blocks Raise the platform approximately 12 feet 3 6 m D Result
179. rs 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 How to Remove the Lift Cylinder GS 2669 DC and GS 3369 DC Bodily injury hazard This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is strongly recommended AWARNING Note When removing a hose assembly or fitting the O ring if equipped on the fitting and or hose end must be replaced All connections must be torqued to specification during installation Refer to Specifications Hydraulic Hose and Fitting Torque Specifications 1 Remove the platform Refer to Repair Procedure How to Remove the Platform 2 Disassemble the scissor assembly Refer to Repair Procedure for your model How to Disassemble the Scissor Assembly GS 2669 DC and GS 3369 DC 1 platform down solenoid valve 2 lift cylinder 3 pressure switch AS CE models GS 4069 DC 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 compon
180. rt circuit except platform as long as GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed H092 H092 COILFAULT Open circuit of the accumulator Open circuit in accumulator harness All functions inhibited ACCUM Open circuit Accumulator coil open circuit except platform as long as GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed H093 H093 COILFAULT Short circuit of the accumulator Short circuit in accumulator harness All functions inhibited ACCUM Bat circuit to battery positive Accumulator coil short circuit except platform as long as GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed H105 H105 COILFAULT Short circuit of the oscillate supply Short or open circuit in oscillate supply harness All functions inhibited OSC SUPPLY circuit to battery positive negative or Oscillate supply coil short or open circuit except platform as long as open circuit GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed H116 H116 COILFAULT Short circuit of the outrigger supply Short or open circuit in outrigger harness All functions inhibited EXTEND RETRACT circuit to battery positive negative or Outrigger supply coil short or open circuit except platform as long as open circu
181. rvice Manual eh a Checklist C Procedures 10 11 12 13 34 Lower the platform onto the safety arm Turn the key switch to the off position Securely install the limit switch to the lower slider channel Turn the key switch to ground control and fully raise the platform Result The platform should stop raising at maximum height An alarm should not sound Result The platform does not raise to maximum height OR an alarm sounds Refer to Repair Procedure How to Calibrate the Platform Overload System if equipped Lower the platform enough to return the safety arm to the stowed position Lower the platform to the stowed position January 2015 C 2 Down Limit Switch Descent Delay if equipped Check the Descent Delay Function Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Application of lubrication to the platform overload mechanism is essential to safe machine operation Continued use of an improperly greased platform overload mechanism could result in the system not sensing an overloaded platform condition and will result in component damage 1 Turn the key switch to platform controls 2 Raise the platform approximately 10 ft 3 m 3 Lower the platform until the down limit switch activates and the platform stops lowering Quickly release the controls and then immediately attempt to lower the platform to the stowed position
182. s e e Genie situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series of steps 44 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Platform controls The platform controls are used to operate the machine from the platform Activating a function button sends a signal to the Electronic Control Module ECM When the ECM is in the function mode the platform controls are used to operate the various machine functions The platform controls consist of an Emergency Stop button electronic circuit board proportional control handle drive steer enable switch alarm function buttons and LED display For further information or assistance contact Genie Product support gt 1 red Emergency Stop button P2 2 platform controls circuit board U3 3 proportional control handle and drive steer enable switch JC9 4 alarm H1 Platform Controls Operational Indicator Codes These codes are generated by the electrical system to indicate machine operating sta
183. s iese ee se ee ee ke ee 30 B 12 Check the Electrical ContactOF ese ee se ee ee ee ee Ge AA ee ee 30 B 13 Perform Hydraulic Oil Analysis ees see ee es se sss 31 B 14 Check the Drive Hub Oil Level and Fastener Torque 31 Checklist C ProcedureS esse esse es see see EE EE EE ER EA Ee EE Ee EE Ee nennen nentes 33 C 1 Test the Platform Overload System if eaguipped ii ee ee ee ee 33 C 2 Down Limit Switch Descent Delay if equipped 34 C 3 Replace the Hydraulic Tank Breather Cap Models with optional Hydraulic ON 35 Genie viii GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 WET EE EE RE pee Table of Contents Checklist D Procedures e sesse se ese EE Re EE EE EE EE AE Ee AE Ee oran oran oras oran on ro on Ee Ee nnn nnn 36 D 1 Check the Scissor Arm Wear Pads and Slider Blocks 36 D 2 Replace the Hydraulic Filter ese ee ee ke ee Ge ke ee Ke Ge Ke ee Ak ke ee ee de 36 D 3 Replace the Drive Hub OH 37 D 4 Test the Function Pump cece ee ER RA ee ee ee GR ee Re ee ee nennen 38 Checklist E Procedures ever EE NEER NESER ENE ENEE GENRE RR RE RR ee PRX KRR RENE RR EE SEK KAREE RE 39 E 1 Test or Replace the Hydraulic OU 39 E 2 Grease the Steer Axle Wheel Bearings sss 40 Section 4 Repair Procedufes RE PE A ERRR RERRNERRERN 43 INTO UC e EE OR HE 43 IS Ela ele fe ge ET
184. side or up and down movement Proceed to step 10 Result There is side to side or up and down movement Proceed to step 6 Remove the dust cap from the hub Remove the cotter pin from the castle nut Tighten the castle nut to 150 ft lbs 203 Nm to seat the bearings Fully loosen the castle nut and re tighten to 35 ft lbs 48 Nm Check for wheel bearing wear by attempting to move the wheel hub side to side then up and down Result There is no side to side or up and down movement Proceed to step 10 Result There is side to side or up and down movement Proceed to step 10 and replace the wheel bearings with new ones Note When replacing a wheel bearing both the inner and outer bearings including the pressed in races must be replaced 10 11 12 Part No 214415 Remove the dust cap from the hub Remove the cotter pin from the castle nut Remove the castle nut Pull the hub off of the spindle The spindle washer thrust washer and outer bearing should fall loose from the hub 13 14 15 16 18 19 20 21 22 Service Manual Checklist E Procedures Place the hub on a flat surface and gently pry the bearing seal out of the hub Remove the rear bearing Pack both bearings with clean fresh grease Place the large inner bearing into the rear of the hub Install a new bearing grease seal into the hub by pressing it evenly into the hub until it is flush Slide the hub onto the yok
185. sition and push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Locate the level sensor in the ground controls compartment Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 73 Service Manual January 2015 Ground Controls al Install the new level sensor onto the machine 6 Connect the wire harness to the level sensor with the X on the level sensor base towards the steer end of the machine Install and tighten the level sensor retaining fasteners 7 Adjust the level sensor retaining fasteners until the bubble in the top of the level sensor is centered in the circles ADANGER Tip over hazard The tilt level Note Be sure there are threads showing through Soto must be installed with the the top of the adjusting fasteners X on the level sensor base towards the steer end of the 8 Calibrate the new level sensor Refer to machine Failure to install the tilt Repair Procedure How to Install and level sensor as instructed could Calibrate the Level Sensor result in the machine tipping over causing death or serious injury g 5 E UCM SY OS BoN E N OS M 1 chassis 2 level sensor 3 Y indicator 4 X indicator Lo Gai 1 1 1 74 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 4 6 Service Override Mode The Electronic Control
186. speed raised every 4000 hours B 11 Module tray latch Two yearor A B C D E B 12 Electrical contactor every B 13 Hydraulic oil 2000 hours analysis B 14 Drive hub oil Comments Use the step by step procedures in this section to learn how to perform these inspections e If any inspection receives an N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired P Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 15 Service Manual January 2015 A eee F This page intentionally left blank Gri 16 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual A 1 Inspect the Manuals and Decals Genie specifications require that this procedure be performed every 8 hours or daily whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the platform An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operation Decals alert operators and personnel to the many possible
187. such as Off level Overload Cutout Chassis Mode Operation during normal operation These codes are not indicators of a device malfunction in the electrical system Code Condition LL Off Level OL Platform Overload CE and Australia CH Chassis Mode Operation nd No Drive option Ld Lifting Disabled option Diagnostic Trouble Codes DTC These codes are generated by the system to indicate that a device or circuit malfunction has been detected in the electrical system The types of Diagnostic Trouble Codes that may occur are explained below Type HXXX Indicate a malfunction associated with devices that control hydraulic functions in the electrical system The HXXX faults are divided into short circuit battery negative short circuit to battery positive open circuit and generic shorts Examples of these devices are solenoid controlled hydraulic valves and motor controller Type PXXX Indicate a malfunction associated with power type devices in the electrical system The PXXX faults are divided into short circuit to battery negative short circuit to battery positive open circuit and generic shorts Examples of these devices are horns sensor power and alarms Type UXXX Indicate a malfunction associated with user interface devices in the electrical system The UXXX faults are divided into short circuit to battery negative short circuit to battery positive open circuit and generic shorts
188. switch circuit All functions inhibited FAULT TYPE 5 GCON ECM C006 C006 GCON ECM GCON input redundancy error Input conditioning circuit failure All functions inhibited FAULT TYPE 6 GCON ECM C007 C007 GCON ECM GCON ECM inter processor Incorrectly programmed device All functions inhibited FAULT TYPE 7 Error in loading software on device GCON ECM C008 C008 GCON ECM GCON ECM temperature sensor Temperature greater than 257 F 125 C Engine functions may be FAULT TYPE 8 error Temperature less than 67 F 55 C inhibited due to glow plug GCON ECM timing C009 C009 GCON ECM GCON fault type 9 Contact Genie support FAULT TYPE 9 C021 C021 PCON NOT Communication failure between CAN communication failure All functions inhibited DETECTED GCON and PCON CAN communication harness PCON unplugged GCON or PCON ECM C023 C023 MACHINE Discrepancy between model Incorrect machine model programmed All functions inhibited MODEL FAULT detected and model programmed GCON or PCON ECM C024 C024 PARAMETER Invalid machine parameters Incorrect machine parameter programmed All functions inhibited PROGRAM FAULT GCON or PCON ECM C025 C025 SYSTEMFAULT Platform overload system not Platform overload system not calibrated All functions inhibited PLAT OVLD NOCAL calibrated GCON or PCON ECM C028 C028 SERVICE Machine is in service override mode Machine programmed for use in service override mode All functions
189. symbol to avoid possible injury or death ADANGER Indicates a imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Indicates a potentially hazardous situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps D Indicates that an incorrect result has occurred after performing a series of steps Maintenance Symbols Legend Note The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that dealer service will be required to perform this procedure Indicates that a cold motor or pump will be required to perform this procedure Genie 12 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual A Eee Scheduled Maintenance Procedures Pre delivery Preparation Report The pre delivery preparation report contains checklists for e
190. t 12 2 m apart 2 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Press the drive function select button 4 Choose a point on the machine i e contact patch of a tire as a visual reference for use when crossing the start and finish lines 5 Bring the machine to top drive speed before reaching the start line Begin timing when your reference point on the machine crosses the start line 6 Continue at full speed and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Checklist B Procedures B 10 Test the Drive Speed Raised Position Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Proper drive functions are essential to safe machine operation The drive function should respond quickly and smoothly to operator control Drive performance should also be free of hesitation jerking and unusual noise over the entire proportionally controlled speed range 1 Create start and finish lines by marking two lines on the ground 40 feet 12 2 m apart 2 _ Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls Raise the platform approximately 6 ft 2 m 4 Press the drive function select button Choose a point on the machin
191. t rear DCON or GCON ECM If machine is in stowed position all functionality is resumed F070 F070 SWITCHFAULT Platform down safety and Open or short circuit of the plattorm down safety and or All functions inhibited DOWN LIMIT MISM operational limit switches are not in operational limit switches the same state Open or short circuit of the plattorm down safety and or operational limit switch harness Faulty safety and or operational limit switch Right rear DCON or GCON ECM F071 F071 MOTOR Drive motor s thermal sensor has One or both drive motors over heated All drive and steer THERM PROTECTION exceeded 185 85 C Faulty thermal sensor in rear drive motor functions inhibited Faulty rear drive motor Left or right rear DCON or GCON ECM Genie A TEREX BRAND 140 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Baas EE ER A Fault Codes Type CXXX Faults DTC 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 Short circuit in the master switch circuit All functions inhibited FAULT TYPE 4 GCON ECM C005 C005 GCON ECM GCON ECM safety switch error Short circuit in the safety
192. tch Left rear outrigger LR RIGGER BAT limit switch to battery negative Short circuit in outrigger harness inhibited if outrigger GCON ECM extend is activated Outrigger can still be retracted F043 F043 SWITCHFAULT Short circuit of the right rear Short circuit of the right rear outrigger limit switch Right rear outrigger RR RIGGER Bat outrigger limit switch to battery Short circuit in outrigger harness inhibited if outrigger positive GCON ECM extend is activated Outrigger can still be retracted F044 F044 SWITCHFAULT Short circuit of the right rear Short circuit of the right rear outrigger limit switch Right rear outrigger RR RIGGER BAT outrigger limit switch to battery Short circuit in outrigger harness inhibited if outrigger negative GCON ECM extend is activated Outrigger can still be retracted F045 F045 SWITCHFAULT Short circuit of the left axle Short circuit of the left axle operational limit switch All functions inhibited LEFT AXLE Bat operational limit switch to battery Short circuit in axle limit switch harness except platform as long as positive GCON ECM machine is in the elevated position If machine is in stowed position all functionality is resumed F046 F046 SWITCHFAULT Short circuit of the left axle Short circuit of the left axle operational limit switch All functions inhibited LEFT AXLE BAT operational limit switch to battery Short circuit in axle limit switch harness except platform as
193. tenance Procedure Test or Replace the Hydraulic Oil Checklist B Procedures B 14 Check the Drive Hub Oil Level and Fastener Torque Genie specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Failure to maintain proper drive hub oil levels may cause the machine to perform poorly and continued use may cause component damage Drive the machine until one of the two plugs is at the highest point 1 drive hub plugs 2 Remove the plug located at 90 degrees and check the oil level Result The oil level should be even with the bottom of the hole Note If necessary remove the top plug and add oil until the oil level is even with the bottom of the hole Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 31 Part No 214415 Service Manual January 2015 A E E Checklist B Procedures 3 Apply pipe thread sealant to the plugs and install the plugs 4 Repeat steps 1 through 4 for the other drive hub 5 Check the torque of the drive hub mounting bolts Refer to Specifications Machine Specifications Gri 32 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual C 1 Test the Platform Overload System if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first OR when the machine fails to lift the maximum rated load Testing the pl
194. the down limit switch Too much weight in platform Put correct rated load in platform Overload system not adjusted properly Turn the pressure switch nut 1 4 turn into the hydraulic line or repeat calibration procedure Part No 214415 Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC 115 Service Manual January 2015 Platform Overload Components 11 2 Platform Overload Recovery Message If the ground controls LCD screen displays OL PLATFORM OVERLOADED the emergency lowering system has been used while the platform was overloaded How to Clear the Platform Overload Recovery Message Note This message shall be cleared by a person trained and qualified on the troubleshooting and repair of this machine Note Use the following chart to identify the description of each LCD screen control button used in this procedure 3 4 Vj Escape Scroll up Scroll down Enter 1 Turn the key switch to the ground controls position and pull out the red Emergency Stop button to the on position at the platform controls 2 Press and hold the ground control scroll up and scroll down buttons a Genie 116 GS 2669 DC GS 3369 DC GS 4069 DC Pull out the red Emergency Stop button at the ground controls Result The ground control LCD display will show the following LIFT SETUP TEST SELECT MODEL DI Press the scroll down button Result The ground control LCD dis
195. the front or rear XA How to Install and Calibrate the K Ke Level Sensor a ADANGER Tip over hazard Failure to install or calibrate the level sensor as jo UN J instructed will compromise KN machine stability and cause the STOP machine to tip over resulting in death or serious injury Do not install or calibrate the level E e KCN sensor other than specified in Ford uu this procedure gt E _ m es Note Perform this procedure with the machine on C O a firm level surface and the platform in the stowed position Use a digital level to confirm 1 auxiliary enable toggle switch 2 auxiliary lowering toggle switch 1 Remove the platform controls from the platform Note If you are not installing a new level sensor or you have installed an outrigger level sensor proceed to step 7 Genie 70 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Ground Controls 2 Locate the level sensor in the ground controls compartment 1 n i gt X cere gt IS BEN OD AO LAC N 1 ground control box 2 level sensor 1 chassis 3 Tag and disconnect the level sensor wire 2 level sensor harness from the chassis wire harness 3 Y indicator 4 X indicator 4 Remove the level sensor retaining fasteners and ies the level sensor from the 6 Connect the wire ha
196. the platform to the stowed position Remove the test weight 114 Q Limit switch legend 1 down limit switch 2 load sense interrupt limit switch 3 maximum height limit switch Genie GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Platform Overload Components Platform Overload System Troubleshooting Condition Cannot lift rated load Possible Cause Relief valve set too low Solution Increase relief valve pressure At max Height with rated load in platform pressure switch alarm continues to sound At down limit with rated load in platform the pressure switch alarm continues to sound System needs to be reset Turn off red emergency stop button wait three seconds and turn machine back on Max Height limit switch out of adjustment or faulty Lower the up limit switch slightly or replace contacts Too much weight in platform Pressure switch out of adjustment Batteries are not fully charged Put correct rated load in platform Turn the pressure switch nut 1 4 turn into the hydraulic line Charge batteries Overload system not adjusted properly Repeat calibration procedure Slider channel not lubricated System needs to be reset Lubricate the slider channel Turn off red emergency stop button wait three seconds and turn machine back on Down limit switch out of adjustment Raise
197. tinue to hold the Enter button until calibration is complete If the Enter button is released return to step 10 and procedure repeat this STEER VAL REQUESTING LEFT y S 7 STEER VAL N REQUESTING RIGHT Y STEERING LEFT KEEP HOLDING DI J Ke STEERING RIGHT KEEP HOLDING EI gt N k CALCULATING DATA KEEP HOLDING EI N Part No 214415 Hydraulic Pump Result The ground controls LCD displays the following screen Calibration data is within range PUMP CAL COMPLETE Note The screen will return to the options screen after 2 seconds D 12 13 Genie ATEREX BRAND Result The ground controls LCD displays the following screen Calibration data is not within range The pump needs to be repaired or replaced PUMP NEEDS SERVICED For a bad result press the Enter button to return to the option screen Push in the red Emergency Stop button to the off position GS 2669 DC GS 3369 DC GS 4069 DC 79 Service Manual January 2015 eet Manifolds 6 1 Function Manifold Components The function manifold is located inside the hydraulic compartment Index Schematic No Description Item Function Torque 1 Check valve FA Oscillate circuit 20 ft lbs 27 Nm 2 Solenoid Valve 2 position 3 way FB Oscillate Accumulator 20 ft lbs 27 Nm Orifice FC 3 Relief valve FD
198. tion inhibited RR RIGGER circuit to battery positive negative or Right rear outrigger coil short or open circuit open circuit GCON ECM H078 H078 COILFAULT Short circuit of the platform down Short or open circuit in platform down 1 harness Platform down function inhibited PLAT DOWN 1 1 circuit to battery positive negative Platform down 1 coil short or open circuit or open circuit GCON ECM H080 H080 COILFAULT Short circuit of the steer left circuit to Short or open circuit in steer left harness Steer left function inhibited STEER LEFT battery negative or open circuit Steer left coil short or open circuit GCON ECM H081 H081 COILFAULT Short circuit of the steer right circuit to Short or open circuit in steer right harness Steer right function inhibited STEER RIGHT battery negative or open circuit Steer right coil short or open circuit GCON ECM H082 H082 COILFAULT Short circuit of the oscillate supply Short circuit in oscillate supply harness All functions inhibited except platform OSC SUPPLY Bat circuit to battery negative Oscillate supply coil short circuit down as long as machine is in the GCON ECM elevated position If machine is in stowed position all functionality is resumed H083 H083 COILFAULT Open circuit in the oscillate supply Short circuit in oscillate supply harness All functions inhibited except platform OSC SUPPLY Open circuit Oscillate supply coil short circuit down as long as mach
199. tton at the platform controls is pushed in the ground controls LCD will display Platform EStop Depressed The machine alarm will sound at 1 beep per second Genie 26 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual B 6 Test the Key Switch Genie requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper key switch action and response is essential to safe machine operation The machine can be operated from the ground or platform controls and the activation of one or the other is accomplished with the key switch Failure of the key switch to activate the appropriate control panel could cause a hazardous operating situation Note Perform this procedure from the ground using the platform controls Do not stand in the platform 1 Pull out the red Emergency Stop button to the on position at both the ground and platform controls 2 Turn the key switch to platform control 3 Check the platform up down function from the ground controls Result The machine functions should not operate 4 Turn the key switch to ground control Check the machine functions from the platform controls Result The machine functions should not operate 6 Turn the key switch to the off position Result No function should operate Checklist B Procedures B 7 Test the Automotive style Horn if equipped Genie requires that this procedure be
200. tus During normal operation a code will appear in the platform controls LED readout if a condition such as off level overload cutout chassis mode operation or pothole guards stuck occurs If the platform controls LED readout displays an operational indicator code such as LL the fault condition must be repaired or removed before resuming machine operation Push in and pull out the red Emergency Stop button to reset the system Platform Controls LED Readout Code Condition LL Off Level OL Platform Overload CE and Australia CH Chassis Mode Operation nd No Drive option F053 DCON RR Thermal Protection F054 DCON LR Thermal Protection F055 Traction Motor RR F056 Traction Motor LR Ld Lifting Disabled option St Engine Start Delay Note A code and a description of a code can also be viewed at the ground controls LCD display Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 45 Service Manual January 2015 Platform Controls 1 1 Circuit Board How to Remove the Platform Controls Circuit Board 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Disconnect the platform controls from the control cable at the platform 3 Remove the fasteners securing the platform control box to the platform control bracket 4 Remove the fasteners securing the bottom cover to the platform
201. ued Fault Codes DTC Message on Description Possible Causes Failure Mode Number GCON LCD U033 U033 JSTICKFAULT PCON drive joystick signal is PCON drive joystick is not in neutral position range at All drive and steer OUT OF CAL RANGE outside acceptable calibration system startup functions inhibited PCON joystick GCON ECM U034 U034 JSTICKFAULT Short circuit of the PCON drive Short circuit of the PCON drive joystick signal circuit All drive and steer OUT OF RANGE HI joystick signal to battery positive at PCON joystick functions inhibited system startup GCON ECM U035 U035 JSTICKFAULT Short circuit of the PCON drive Short circuit of the PCON drive joystick signal circuit All drive and steer OUT OF RANGE LO joystick signal to battery negative at PCON joystick functions inhibited system startup GCON ECM U036 U036 SWITCHFAULT Mis wiring or short circuit of GCON Short circuit of the GCON key switch harness All functions inhibited GCON PCON ON key switch GCON key switch GCON ECM U037 U037 SWITCHFAULT Foot switch or Enable switch Enable switch activated at startup All drive and steer FOOTSW PRESSED depressed at startup Enable switch contact stuck closed unctions inhibited PCON ECM U038 U038 SWITCHFAULT Short circuit of the PCON power Short circuit in PCON power harness All drive and steer FOOTSWITCH Bat circuit to enable switch to battery Enable sw
202. und controls LCD display will Relief Valve SHOW INE NINE Models without Platform Overload DOWN DELAY WEN Note Verify the hydraulic oil level is within the top IS NOW ON 2 inches 5 cm of the sight gauge 1 Connect a 0 to 5000 psi O to 350 bar Note After 1 second the display will return to pressure gauge to test port 1 TP1 on the SELECT OPTION DOWN DELAY function manifold SELECT OPTION DOWN DELAY 51 Push in the red Emergency Stop button to the off position 52 Perform Maintenance Procedures Test the Platform overload System and Down Limit Switch Decent delay 1 platform up relief valve 2 test port 1 Gri 90 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual and EE EE RE RE Manifolds 2 Using a suitable lifting device place and secure the maximum rated load in the center of the platform deck GS 2669 1500 Ibs 680 kg GS 3369 1000 Ibs 454 kg GS 4069 800 Ibs 363 kg 3 Press and hold the lift function enable button and platform up button Allow the platform to raise completely then continue activating the lift function while observing the pressure reading on the pressure gauge Note the pressure Refer to Specifications Hydraulic Component Specifications 4 Hold the lift relief valve with a wrench and remove the cap 5 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decre
203. ure Connect the harness back to the original position Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 83 Service Manual January 2015 Manifolds How to Adjust the Steer Relief Valve Note Perform this procedure with the machine in the stowed position 1 Connect a 0 to 5000 psi O to 350 bar pressure gauge to test port 1 TP1 on the function manifold 2 Remove the platform controls from the platform and place the controls near the function manifold on the hydraulic tank side of the machine 3 Turn the key switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Steerthe machine fully to the right or left and hold Note the pressure reading on the pressure gauge Refer to Specifications Hydraulic Components Specifications 5 Usea wrench to hold the steer relief valve and remove the cap 6 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap AWARNING _ ip over hazard Do not adjust the relief valve higher than specified 7 Repeat this procedure beginning with step 4 to confirm the relief valve pressure Genie Remove the pressure gauge 1 test port 1 2 steer relief valve 84 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual
204. ure to properly dispose of old oil or other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated and well lit Part No 214415 January 2015 a eee Table of Contents Introduction lite HI d D ii Important Information 2 2 0 2 se ee ee cece ER RA Ge ER EA AA Ge ee ee ee Ge Re Re ee ee ee ee ee Re de ee ee ee ii Serial Number Information ee ee ER ER RA Ee Ee GR EA RA Re Ge ee ee ee ee ee Re Re ee ee ee ee ee ii REVISION HIS osnan OE EE M iii Serial Number Legend sico ata dd iv Section 1 A o saeueeescaaceeasecberentceneterecceueey es v General Safety Rules ie ee se AA Ee GR GR AA Ge ee ee ee GR Ee Re Re ee ee ee ee ee ee Re Re ee ee ee ee ee V Section 2 Specifications iii ra oa SERE EE N 1 Machine Gpechftcatons iese ee ER Ee RA Ee ee ER ER Ge RA ee ee ee Re AA nnne 1 Performance Specifications see ee ee Ee ee ER Ee AA Ee ee ee Ee ai ee ee nens 2 Hydraulic SPOCCAtlON EE OE EE sidad 3 Hydraulic Component Gpechficatons see ee ee ee ee Ee Re Re Ee ee ee Ge ee ee ee ee ee ee ee nano 5 Manifold Component Specifications 5 Battery Specific OS viciado a e Ra D ERR DR Red dg 6 Hydraulic Hose and Fitting Torque Specifications iese ees se ee ee se ke ee ek ee ee ee 7 Torque Procedure is ERGE ES dte Re dll id 8 SAE and Metric Fasteners Torque Charts 10 Section 3 Scheduled Maintenance Procedures eene 11 A
205. ut WH RD C3 03 Sensor Power Digital Output RD C3 04 Automotive Horn Digital Output WH C3 05 Left Oscillate Limit Switch Digital Input GR BK C3 06 Right Oscillate Limit Switch Digital Input GR C3 07 Down Limit Switch LS6 Digital Input OR C3 08 Digital Level Sensor if equipped Digital Input RD BK C3 09 Platform Overload Pressure Switch platform overload option Digital Input BL C3 10 Platform Overload Pressure Switch platform overload option Digital Input WH BK C3 11 Pump Speed Hz Digital Input OR BK C3 12 Sensor Ground Digital Input BK C4 Connector Brown Outrigger Option C4 01 Left Front Outrigger Limit Switch Digital Input BK C4 02 Right Front Outrigger Limit Switch Digital Input OR C4 03 Left Rear Outrigger Limit Switch Digital Input BL C4 04 Right Rear Outrigger Limit Switch Digital Input GR C4 05 Level Sensor X Axis Analog Input GR WH C4 06 Level Sensor Y Axis Analog Input GR BK C4 07 Left Front Outrigger Coil Digital Output BK WH C4 08 Right Front Outrigger Coil Digital Output OR WH C4 09 Left Rear Outrigger Coil Digital Output BL WH C4 10 Right Rear Outrigger Coil Digital Output GR WH C4 11 Outrigger Extend Coil Digital Output WH RD C4 12 Outrigger Retract Coil Digital Output WH BK Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 123 Service Manual January 2015 Fault Codes Operation Indicator Codes OIC These codes are generated by the electrical system to indicate machine operating status
206. utton to the on position at the platform controls Press and hold the ground control scroll up and scroll down buttons pas Ee P Ground Control Menu Buttons 1 scroll down button 2 enter button 3 scroll up button 4 escape button 5 LCD display Pull out the red Emergency Stop button to the on position at the ground controls Result The ground controls LCD display will show the following LIFT SETUP TEST SELECT MODEL e Release the Scroll Up and Scroll Down buttons after the ground controller powers up Service Manual January 2015 AN Ground Controls 5 Atthe ground controls use the Scroll Down button to scroll to SVC Override Result The ground controls LCD display will show the following LIFT SETUP TEST fT SVC OVERRIDE EI 6 Press the Enter button Result The ground controls LCD display will show the following CONFIRM SERVICE OVERRIDE MODE 7 Pressthe Enter button Result The ground controls LCD display will show the following C028 SERVICE OVERRIDE MODE ON Gri 76 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Hydraulic Pump 5 1 How to Remove the Hydraulic Hydraulic Pump Pump e z 1 Tag disconnect and plug the hydraulic hoses ae pump is a single section gear type on the pump Cap the fittings on the pump Note When removing a hose assembly or fitting AWAR
207. ve the center pivot pins and set aside Carefully lift and separate the linkage assembly apart and place it on a structure capable of supporting it 54 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual ORO amp 9 Part No 214415 Qo OO d Oo KEND o 11 12 Scissor Components amp amp amp 8 9 O9 9 9o O GS 3369 C Steer End Platform pivot Number 4 center pivot pin Qty Number 4 pivot pin steer end Number 3 center pivot pin Qty Lift cylinder rod end pivot pin Number 3 pivot pin steer end Number 2 center pivot pin Qty Number 2 pivot pin steer end Number 1 outer arm Number 1 center pivot pin Qty ANSI CSA Number 1 center pivot pin Qty AS CE Number 1 inner arm Genie ATEREX BRAND GS 2669 DC GS 3369 DC GS 4069 DC O Non steer End Chassis pivot Slider block Qty 2 Number 4 inner arm Number 4 outer arm Number 4 pivot pin non steer end Number 3 inner arm Number 3 outer arm Number 3 pivot pin non steer end Number 2 inner arm Number 2 outer arm Number 2 pivot pin non steer end Lift cylinder barrel end pivot pin Number 1 outer arm 55 Service Manual January 2015 Scissor Components 3 2 Scissor Assembly GS 3369 DC
208. ve the drive motor from the machine 1 axle pivot pin 2 retaining fasteners 3 axle assembly 12 Remove the axle pivot pin retaining fasteners 13 Using a soft metal drift remove the axle pivot pin Remove the axle assembly from the machine 1 axle assembly 2 drive hub 3 retaining fasteners x4 4 drive motor Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 107 Service Manual January 2015 Non steer Axle Components 9 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 Remove the drive motor Refer to Repair 1 axle assembly Procedure How to Remove a Drive Motor 2 o ring 3 retaining fasteners 2 Using a suitable supporting device secure the A dave hub drive hub Do not apply pressure 3 Remove the drive hub retaining fasteners Remove the drive hub CAUTION Crushing hazard The drive hub may become unbalanced and fall if not properly supported and secured with a suitable lifting device when removed from the machine Note There is an O ring between the drive motor and drive hub Be sure that it is in place when installing the drive motor to the drive hub Note Refer to Specifications Fastener Torque Chart Specifications Lo Qai 1 108 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual 10 1 Outrigger Cylinder How to
209. ween return side and signal side of the harness plug of faulted device Result Resistance should be 1M Q or higher OK Go to step 3 No Good Replace or repair harness Check the GCON ECM Gri 126 GS 2669 DC GS 3369 DC GS 4069 DC Part No 214415 January 2015 Service Manual Baas EE i ss 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 Refer to the GCON I O Map in this section to identify the faulted out circuit pin Short to ground resistance should be greater than 5k Q For short to B type faults measure resistance between pins C1 12 driver power and the GCON pin associated with the fault code Refer to the GCON I O Map in this section to identify the faulted out circuit pin Short to power resistance should be greater than 50k Q Replace GCON ECM Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 127 Service Manual January 2015 Ts Fault Codes Type HXXX Faults DTC Message on Description Possible Causes Failure Mode Number GCON LCD HOO1 HOO1 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 Platform up 1 coil short circuit inhibited GCON ECM
210. wer the platform onto the safety arm 17 Pushin the red Emergency Stop button to the off position 18 Locate and disconnect the lift cylinder pressure switch harness 1 maximum height limit switch 20 Secure the maximum height limit switch roller head in the up position Component damage hazard The limit switch will be damaged if it is not properly secured 21 Pull out the red Emergency Stop button to the on position and raise the platform approximately 10 feet 3 m 22 Return the safety arm to the stowed position 23 Lower the platform to the stowed position 1 platform down solenoid valve 2 lift cylinder 3 pressure switch AS CE models Genie ATEREX BRAND Part No 214415 GS 2669 DC GS 3369 DC GS 4069 DC 87 Service Manual January 2015 Manifolds 24 Using a suitable lifting device place and secure the maximum rated load in the center of the platform deck GS 2669 680 kg GS 3369 454 kg GS 4069 363 kg 25 Press and hold the lift function enable button and platform up button Allow the platform to raise completely then continue activating the lift function while observing the pressure reading on the pressure gauge Note the pressure Refer to Specifications Hydraulic Component Specifications 26 Hold the lift relief valve item 1 with a wrench and remove the cap 27 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the

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