Terex Genie GS-2669 BE Service Manual Download Page 62

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Service Manual

May 2015

Repair Procedures

GS-2669 BE • GS-3369 BE • GS-4069 BE

Part No. 1257106

About This Section

Most of the procedures in this section should only

be performed by trained service professional in a

suitably equipped workshop. Select the appropriate

repair procedure after troubleshooting the problem.
Perform disassembly procedures to the point

where repairs can be completed. Then to

re-assemble, perform the disassembly steps in

reverse order.

Symbols Legend

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 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.

Summary of Contents for Genie GS-2669 BE

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

Page 2: ...ter 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 ha...

Page 3: ...2014 Repair Added 12 2 Platform Overload Recovery A2 4 2015 Maintenance C 2 Repair 3 5 7 2 Schematics All Electrical and Hydraulic A3 5 2015 Repair 5 4 Reference Examples Section Maintenance B 3 Elect...

Page 4: ...History Revision Date Section Procedure Page Description Reference Examples Section Maintenance B 3 Electronic Version Click on any content or procedure in the Table of Contents to view the update Sec...

Page 5: ...rt No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE v Serial Number Legend 1 model 2 model year 3 facility code for models manufactured in multiple facilities 4 sequence code 5 serial label stamped on chas...

Page 6: ...jury 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 You are trained and qualifie...

Page 7: ...l 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 mac...

Page 8: ...d v Section 1 Safety Rules vi General Safety Rules vi Section 2 Specifications 1 Machine Specifications 1 Performance Specifications 2 Hydraulic Specification 2 Hydraulic Component Specifications 5 Ma...

Page 9: ...e Maintenance 24 A 8 Replace the Drive Hub Oil 25 Checklist B Procedures 26 B 1 Inspect the Batteries 26 B 2 Inspect the Electrical Wiring 28 B 3 Inspect the Tires Wheels and Castle Nut Torque 29 B 4...

Page 10: ...f equipped 37 Check the Descent Delay Function 38 Check the Down Limit Switch Height 38 C 3 Replace the Hydraulic Tank Breather Cap Models with optional Hydraulic Oil 38 C 4 Perform Engine Maintenance...

Page 11: ...latfrom Controls Alarm 49 1 4 Platfrom Emergency Stop Button 50 Platform Components 51 2 1 Platform 51 2 2 Platform Extension Deck 52 Scissor Components 54 3 1 Scissor Assembly GS 2669 BE 55 3 2 Sciss...

Page 12: ...t the Hydraulic Pump 80 How to Remove the Hydraulic Pump 80 How to Calibrate the Hydraulic Pump 81 Manifolds 83 7 1 Function Manifold Components 83 7 2 Valve Adjustments Function Manifold 85 How to Ad...

Page 13: ...ensor 107 Non steer Axle Components 110 10 1 Drive Motors 110 10 2 Drive Hub 112 Outrigger Components 113 11 1 Outrigger Cylinder 113 11 2 Outrigger Calibration 114 How to Calibrate the Outrigger Syst...

Page 14: ...tion 5 Fault Codes 125 Introduction 125 Operation Indicator Codes OIC 130 Diagnostic Trouble Codes DTC 130 Troubleshooting HXXX and PXXX Faults 131 Fault Inspection Procedure 132 Type HXXX Faults 134...

Page 15: ...Electrical Schematic GS 2669 BE and GS 3369 BE with Proportional Lift ANSI CSA 167 Electrical Schematic GS 4069 BE with 2 Speed Lift AS CE 170 Electrical Schematic GS 4069 BE with Proportional Lift AN...

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Page 17: ...ggers including tank GS 4069 BE 17 5 gallons 66 liters Hydraulic system with outriggers including tank GS 4069 BE 19 gallons 72 liters Drive hub EP 90 or SAE 90 multipurpose hypoid gear oil API servic...

Page 18: ...m 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 corros...

Page 19: ...ium Oil MV Fluid Properties ISO Grade 32 Viscosity index 200 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 7 5 33 5 Brookfield Viscosity cP 4 F 20 C cP 22 F 30 C 1040 3310 Flash point 375 F 190 C...

Page 20: ...viron MV 46 Fluid Properties ISO Grade 46 Viscosity index 154 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 8 0 44 4 Flash point 482 F 250 C Pour point 49 F 45 C Maximum continuous operating temp...

Page 21: ...ri Lift relief valve pressure GS 2669 BE 3100 psi 214 bar Lift relief valve pressure GS 3369 BE 2900 psi 200 bar Lift relief valve pressure GS 4069 BE 2850 psi 197 bar Steer relief valve pressure 1500...

Page 22: ...pacity 225 AH Reserve capacity 25A rate 447 minutes Reserve capacity 75A rate 115 minutes Weight each 63 lbs 29 kg Weight tray with batteries 504 lbs 229 kg T145 Type 6v DC Quantity 8 Capacity 260 AH...

Page 23: ...ncluding filter 1 2 quarts 1 1 liters Oil viscosity requirements Units ship with 15W 40 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the...

Page 24: ...18 1 8 3 4 16 1 10 7 8 14 1 12 1 1 16 12 1 16 1 5 16 12 1 20 1 5 8 12 1 24 1 7 8 12 1 SAE O ring Boss Port tube fitting installed into Aluminum all types SAE Dash Size Torque 4 14 ft lbs 19 Nm 6 23 f...

Page 25: ...ed and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque Refer to the a...

Page 26: ...ct 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...

Page 27: ...May 2015 Service Manual Specifications Part No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE 11...

Page 28: ...Service Manual May 2015 12 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 This page intentionally left blank...

Page 29: ...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...

Page 30: ...t 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 situatio...

Page 31: ...pre delivery preparation report contains checklists for each type of scheduled inspection Make copies for each inspection Store completed forms as required Maintenance Schedule The Scheduled Maintena...

Page 32: ...Service Manual May 2015 16 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 This page intentionally left blank...

Page 33: ...d service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Instructions Use the operator s manual on your machine The Pre delivery...

Page 34: ...Service Manual May 2015 18 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 This page intentionally left blank...

Page 35: ...e 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 Checklist A Y N R A 1 Inspect the manuals and decals...

Page 36: ...Service Manual May 2015 20 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 This page intentionally left blank...

Page 37: ...ld 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 manua...

Page 38: ...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...

Page 39: ...is designed so that all four tires maintain firm contact to the ground on unlevel terrain improving traction and machine stability Proper axle oscillation is essential to safe machine operation If th...

Page 40: ...ut Torque B 14 Check the Oil Level in the Drive Hubs A 7 Perform Engine Maintenance The 50 hour maintenance procedure is a one time sequence of procedures to be performed after the first 30 days or 50...

Page 41: ...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 machi...

Page 42: ...alant will help eliminate corrosion on the battery terminals and cables 2 Be sure that the battery retainers and cable connections are tight 3 Be sure that the battery separator wire connections are t...

Page 43: ...isplay 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 cell...

Page 44: ...could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the underside of the chassis for damaged or missing ground strap s 2 Inspect the following areas for burnt...

Page 45: ...r 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 3 Remove the castle nut cotter pin and check each castle nu...

Page 46: ...ency 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 button at the platfor...

Page 47: ...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 appea...

Page 48: ...and note the time when the machine reference point crosses the finish line Refer to Specifications Performance Specifications B 10 Test the Drive Speed Raised Position Genie specifications require th...

Page 49: ...all rings watches and other jewelry Note Replace the contactor if any damage is found B 12 Perform Hydraulic Oil Analysis Genie specifications require that this procedure be performed every 250 hours...

Page 50: ...ote Perform this procedure with the engine off 1 Remove the fuel filler cap from the tank 2 Check for proper venting Result Air passes through the fuel tank cap Proceed to step 4 Result If air does no...

Page 51: ...d use may cause component damage 1 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...

Page 52: ...on at both ground and platform controls 2 Raise the platform approximately 10 feet 3 m 3 Lift the safety arm and move it to the center of the linkage and rotate to a vertical position 4 Lower the plat...

Page 53: ...wn Limit Switch Descent Delay if equipped Genie specifications require that this procedure be performed every 500 hours or six months whichever comes first Application of lubrication to the platform o...

Page 54: ...ht 1 Raise the platform approximately 10 ft 3 m 2 Lower the platform until the down limit switch activates and the platform stops lowering 3 Push in the red Emergency Stop button to the off position 4...

Page 55: ...ire that this procedure be performed every 500 hours or annually whichever comes first Fuel tank Oil level Oil filter Fuel filter Rocker arm Injectors Required maintenance procedures and additional en...

Page 56: ...machine Result The measurement is 1 4 inch 6 35 mm or more Proceed to step 3 Result The measurement is less than 11 32 inch 8 71 mm Replace both upper and lower slider wear pads D 2 Replace the Drive...

Page 57: ...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 At the ground controls...

Page 58: ...tting 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 Push in the red E...

Page 59: ...add if needed 23 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...

Page 60: ...gs including the pressed in races must be replaced 10 Remove the dust cap from the hub Remove the cotter pin from the castle nut 11 Remove the castle nut 12 Pull the hub off of the spindle The spindle...

Page 61: ...ropriate 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 adher...

Page 62: ...lert 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 w...

Page 63: ...Operati onal Indicator Codes Operational Indicator Codes These codes are generated by the electrical system to indicate machine operating status During normal operation a code will appear in the platf...

Page 64: ...harged 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 Maint...

Page 65: ...s when handling printed circuit boards OR use a grounded wrist strap 7 Carefully remove the joystick fasteners 8 Carefully remove the joystick from the platform control box Torque specifications Joyst...

Page 66: ...orm control box Open the control box 5 Disconnect the white wires from the Emergency Stop base Electrocution burn hazard Contact with electrically charged circuits could result in death or serious inj...

Page 67: ...ring 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 f...

Page 68: ...t 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 install...

Page 69: ...on 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 forkli...

Page 70: ...pin Qty 2 6 Number 2 pivot pin steer end 7 Number 1 center pivot pin Qty 2 ANSI CSA 8 Number 1 center pivot pin Qty 1 AS CE 9 Number 1 inner arm Non steer End 10 Chassis pivot 11 Slider block Qty 2 1...

Page 71: ...the linkage assembly Component damage hazard Cables can be damaged if they are kinked or pinched 4 Using a suitable supporting device attach a strap to the rod end of the lift cylinder Do not apply pr...

Page 72: ...arm Make the chains tight but do not apply lifting pressure Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine 20 Remove the...

Page 73: ...y 2 8 Number 2 pivot pin steer end 9 Number 1 outer arm 10 Number 1 center pivot pin Qty 2 ANSI CSA 11 Number 1 center pivot pin Qty 1 AS CE 12 Number 1 inner arm Non steer End 13 Chassis pivot 14 Sli...

Page 74: ...inkage assembly Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 4 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 4 inner a...

Page 75: ...on a structure capable of supporting it 20 Tag and disconnect the harness from the lift cylinder valve block 21 Tag and disconnect the hydraulic hoses from the lift cylinder Plug the hoses and cap th...

Page 76: ...o not apply lifting pressure 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 cen...

Page 77: ...n Qty 2 12 Number 2 pivot pin steer end 13 Number 1 center pivot pin Qty 2 ANSI CSA OR Number 1 center pivot pin Qty 1 AS CE 14 Number 1 inner arm 15 Chassis pivot Non steer End 16 Slider block Qty 2...

Page 78: ...ge assembly Component damage hazard Cables and hoses can be damaged if they are kinked or pinched 4 Using an overhead lifting device attach a 4 hook sling chain to the ends of the number 4 inner arm M...

Page 79: ...ch a strap to the rod end of the lower lift cylinder Do not apply pressure 21 Remove the lower cylinder rod end pivot pin retaining fasteners 22 Using a soft metal drift remove the pivot pin 23 Lower...

Page 80: ...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...

Page 81: ...e to the ladder at the non steer end of the machine Support the ladder Do not apply lifting pressure 2 Remove the fasteners securing the ladder to the chassis Remove the ladder from the machine and se...

Page 82: ...Remove the slider feet by sliding them out of the slider channel 8 Remove the upper and lower wear pads and discard 9 Using a hard rubber mallet secure the upper and lower wear pads to the slider feet...

Page 83: ...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...

Page 84: ...en 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 Specificatio...

Page 85: ...ng from the switch Remove the switch from the engine Burn hazard Beware of hot engine components Contact with hot engine components may result in severe burns 3 Install the new switch and tighten Torq...

Page 86: ...ECM This allows the platform to be raised or lowered at the ground controls Note Steer and drive functions are not available at the ground controls When the ECM is in the set up mode the ground contro...

Page 87: ...ntrols will show CH See example below Result The display at the ground controls will show the machine model and hour meter information See example below 2 Press the ground control scroll down button R...

Page 88: ...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 f...

Page 89: ...is received from the level sensor The tilt alarm sounds when the incline of the chassis exceeds 2 to the side and 3 to the front or rear How to Install and Calibrate the Level Sensor Tip over hazard...

Page 90: ...over hazard The tilt level sensor must be installed with the X on the level sensor base towards the steer end of the machine Failure to install the tilt level sensor as instructed could result in the...

Page 91: ...es 10 cm 17 Remove the blocks from under both wheels 18 Lower the machine and remove the jack 19 Center a lifting jack under the drive chassis at the engine side of the machine 20 Raise the machine ap...

Page 92: ...3 to the front or rear How to Install the Outrigger Level Sensor Tip over hazard Failure to install or calibrate the level sensor as instructed will compromise machine stability and cause the machine...

Page 93: ...ds the steer end of the machine Failure to install the tilt level sensor as instructed could result in the machine tipping over causing death or serious injury 1 chassis 2 level sensor 3 Y indicator 4...

Page 94: ...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 retr...

Page 95: ...und controls use the Scroll Down button to scroll to SVC Override Result The ground controls LCD display will show the following 6 Press the Enter button Result The ground controls LCD display will sh...

Page 96: ...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...

Page 97: ...button 4 escape button 5 LCD display 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 4 Release the Scr...

Page 98: ...il calibration is complete If the Enter button is released return to step 10 and repeat this procedure Result The ground controls LCD displays the following screen Calibration data is within range Not...

Page 99: ...20 ft lbs 27 Nm 6 Flow control valve 1 gpm 3 8 L min FG Controls flow to the oscillate circuit 20 ft lbs 27 Nm 7 Relief valve 3500 psi 241 bar FH System relief 20 ft lbs 27 Nm 8 Relief valve 1500 psi...

Page 100: ...Service Manual May 2015 Manifolds 84 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106...

Page 101: ...ect 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 enab...

Page 102: ...red Emergency Stop button to the on position at both the ground and platform controls 5 Steer the machine to the right and hold Note the pressure readings on the pressure gauge Refer to Specification...

Page 103: ...ontrol and pull out the red Emergency Stop button to the on position at both the ground and platform controls 4 Steer the machine fully to the right or left and hold Note the pressure reading on the p...

Page 104: ...n manifold 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 3 Press...

Page 105: ...r button Result The ground controls LCD display will show the following 9 Press the Enter button Result The ground controls LCD display will show the following Note After 1 second the display will ret...

Page 106: ...Emergency Stop button to the off position 18 Locate and disconnect the lift cylinder pressure switch harness 1 solenoid valve proportional lift models 2 solenoid valve 2 speed lift models 3 lift cylin...

Page 107: ...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 31 Raise the pl...

Page 108: ...play will show the following 46 Press the Enter button Result The ground controls LCD display will show the following 47 Press the Enter button Result The ground controls LCD display will show the fol...

Page 109: ...f position 52 Perform Maintenance Procedures Test the Platform overload System and Down Limit Switch Decent delay How to Adj ust the Pl atform U p R elief Valve Models without Pl atform Overl oad How...

Page 110: ...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 pr...

Page 111: ...S 3369 BE GS 4069 BE 95 7 3 Outrigger Manifold Components The outrigger manifold is located inside the hydraulic compartment Index No Description Schematic Item Function Torque 1 Solenoid valve 3 posi...

Page 112: ...n death or serious injury Remove all rings watches and other jewelry 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...

Page 113: ...attery Connect the other end of the resistor to a terminal on the coil Resistor 10 Genie part number 27287 Note The battery should read 9V DC or more when measured across the terminals 1 multimeter 2...

Page 114: ...el filler cap from the tank 2 Using an approved hand operated pump drain the fuel tank into a suitable container Refer to Specifications Machine Specifications Note Be sure to only use a hand operated...

Page 115: ...rque Specifications 1 Remove the hydraulic tank cap 2 Remove the drain plug from the hydraulic tank and completely drain the tank into a container of suitable capacity Refer to Specifications Machine...

Page 116: ...ssis 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 Left side yoke 7 Remove the re...

Page 117: ...tener 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 Crushing hazard The assembly may become unbalanced and fall if not properl...

Page 118: ...sure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the rue ring from each cylinder clevis pin Remove the clevis pins 3 Remove the steer cylinder from the machine 9 3 Tie Rod How...

Page 119: ...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...

Page 120: ...e 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 a...

Page 121: ...y are in a straight driving position 2 Turn the key switch to the off position 3 Push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key swi...

Page 122: ...or bracket 4 cable restraint 5 steer sensor 6 steer sensor spacer 7 steer sensor mounting plate 12 Pull the sensor harness through the cable restraint and sensor bracket 13 Remove the retaining fasten...

Page 123: ...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 How to C alibr...

Page 124: ...Result The ground controls LCD display will show the following 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...

Page 125: ...ht 15 Press the Enter button Result The ground controls LCD display will show the following 16 Use the platform drive controller steer function to turn the steer tires fully to the left 17 Press the E...

Page 126: ...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...

Page 127: ...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...

Page 128: ...orting device secure the drive hub Do not apply pressure 3 Remove the drive hub retaining fasteners Remove the drive hub Crushing hazard The drive hub may become unbalanced and fall if not properly su...

Page 129: ...onnect and plug the hydraulic hoses from the outrigger cylinder Cap the fittings on the cylinder Bodily injury hazard Spraying hydraulic oil can penetrate and burn skin Loosen hydraulic connections ve...

Page 130: ...t Support How to C alibr ate the Outri gger System 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...

Page 131: ...vement 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 b...

Page 132: ...urn 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 3 m 6 Lower the plat...

Page 133: ...eck the Maximum H eight Limit Switch 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 R...

Page 134: ...ad Components 118 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 8 Lower the platform to the stowed position Remove the test weight Limit switch legend 1 down limit switch 2 load sense interrupt lim...

Page 135: ...ntacts Too much weight in platform Put correct rated load in platform Pressure switch out of adjustment Turn the pressure switch nut 1 4 turn into the hydraulic line Batteries are not fully charged Ch...

Page 136: ...ing chart to identify the description of each LCD screen control button used in this procedure Escape Scroll up Scroll down Enter 1 Turn the key switch to the ground controls position and pull out the...

Page 137: ...8 Press the enter button Result The ground control LCD display will show the following 9 Press the buttons in the following sequence down down up enter Note After each key press an asterisk will appea...

Page 138: ...harger is replaced no adjustments are required unless your machine is equipped with AGM batteries If the boost charger is replaced the charger must be set correctly to properly operate To properly set...

Page 139: ...onnection 4 selector curve 5 not used 6 AC input 1 LED is red during phases I1 and P bulk charger 20 battery charged 2 LED is yellow during phases U and I2 80 battery charged 3 LED is green at the end...

Page 140: ...Service Manual May 2015 124 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 This page intentionally left blank...

Page 141: ...d 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 eac...

Page 142: ...ie 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 Dia...

Page 143: ...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 displ...

Page 144: ...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 Inp...

Page 145: ...Input BL RD 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...

Page 146: ...y 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 as...

Page 147: ...ctor between Ground Controls and faulted device No Good Repair or replace harness an or connector Good No Good 3 Check GCON Electronic Control Module ECM Replace ECM Wiring Diagram The wiring diagram...

Page 148: ...ntactor Coil 47 OK Go to step 2 No Good Replace faulted device 2 Check the harness between the ground controls and the faulted device 1 Disconnect the GCON ECM connectors C1 C2 and C3 or C4 if equippe...

Page 149: ...in associated with the fault code Refer to the GCON I O Map in this section to identify the faulted out circuit pin 3 Short to ground resistance should be greater than 5k 4 For short to B type faults...

Page 150: ...AULT O R EXTEND Bat Short circuit of the outrigger extend coil to battery negative Short circuit in outrigger extend coil harness Outrigger extend coil short circuit GCON ECM Only outrigger extend fun...

Page 151: ...er left circuit to battery negative or open circuit Short or open circuit in steer left harness Steer left coil short or open circuit GCON ECM Steer left function inhibited H081 H081 COILFAULT STEER R...

Page 152: ...2 COILFAULT ACCUM Open Open circuit of the accumulator circuit Open circuit in accumulator harness Accumulator coil open circuit GCON ECM All functions inhibited except platform as long as machine is...

Page 153: ...rness GCON ECM All functions inhibited P018 P018 PWRFAULT PCON POWER Bat Short circuit of the PCON power circuit to battery negative Short circuit in PCON power harness GCON ECM All functions inhibite...

Page 154: ...f the brake relay contact or coil Short or open circuit in brake relay harness Brake relay contact stuck closed Faulty brake relay GCON ECM All functions inhibited P040 P040 COILFAULT BRAKE PWR OPEN S...

Page 155: ...Short in motor controller harness Faulty left DCON ECM Batteries will not charge correctly in generator mode P049 P049 CHRGR FAULT Boost Bat Short circuit of the boost battery charger circuit to batt...

Page 156: ...nu functions inhibited U005 U005 SWITCHFAULT GCON LCD DOWN Short circuit of the GCON LCD scroll down switch at system startup Short circuit of the GCON LCD scroll down switch GCON ECM All GCON LCD men...

Page 157: ...witch contact stuck closed PCON ECM All drive and steer functions inhibited U038 U038 SWITCHFAULT FOOTSWITCH Bat Short circuit of the PCON power circuit to enable switch to battery positive Short circ...

Page 158: ...itive Short circuit of the left front outrigger limit switch Short circuit in outrigger harness GCON ECM Left front outrigger inhibited if outrigger extend is activated Outrigger can still be retracte...

Page 159: ...e inhibited at 221 F 105 C F057 F057 MOTOR RR ENCODER FAULT Return signal from the right rear drive motor encoder to the right rear drive controller is 40 Hz or higher Short or open circuit of the dri...

Page 160: ...al limit switches Open circuit of the right and or left axle safety or operational limit switch harness Right rear DCON or GCON ECM All functions inhibited except platform as long as machine is in the...

Page 161: ...GCON or PCON ECM All functions inhibited C025 C025 SYSTEMFAULT PLAT OVLD NOCAL Platform overload system not calibrated Platform overload system not calibrated GCON or PCON ECM All functions inhibited...

Page 162: ...losed Right rear DCON or GCON ECM All functions inhibited C043 C043 DCON LR ECM FAULT TYPE 07 Open circuit of the key switch circuit or battery positive negative of the left rear drive controller Open...

Page 163: ...he 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 About This Section T...

Page 164: ...mp controls CB4 25 amp 110V AC generator CB4 12 amp 240V AC generator CB4A 15 amp 110V AC generator CB4A 8 amp 240V AC generator CB4B 15 amp 110V AC generator CB4B 8 amp 240V AC generator CB7 15 amp p...

Page 165: ...al LSA1OSS Left axle oscillate safety LSA2OSS Right axle oscillate safety M Motor or Pump M3 Starter M5 Lift pump P Red emergency stop button P1 Ground controls P2 Platform controls PS Pressure switch...

Page 166: ...eft rear outrigger option Y34 Right rear outrigger option Y35 Left front outrigger option Y36 Right front outrigger option Y39 Outrigger retract option Y40 Outrigger extend option Y93 Oscillate left Y...

Page 167: ...lve 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 2 way v...

Page 168: ...e with amperage Circuit breaker with amperage Connection no terminal Circuits crossing no connection Quick disconnect terminal Level sensor without outriggers Power relay Coil solenoid or relay Contac...

Page 169: ...ated 3 position 4 way directional valve Solenoid operated 3 position 5 way directional valve Solenoid operated 2 position 3 way directional valve Solenoid operated 2 position 2 way directional valve F...

Page 170: ...oscillate limit switches LSA10S and LSA10SS 3 right rear outrigger limit switch LS15 4 right axle oscillate limit switches LSA20S and LSA20SS 5 platform overload pressure switch S25 6 right front outr...

Page 171: ...contact 1 Charger not connected to battery or main supply Contact open 2 Charger connected to battery Contact closed 3 Charger connected to battery and main supply Contact open Supply Battery Contact...

Page 172: ...Service Manual May 2015 156 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 This page intentionally left blank...

Page 173: ...May 2015 Service Manual 157 Contactor Box Layout All Models...

Page 174: ...Service Manual May 2015 158 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 Contactor Box Layout All Models...

Page 175: ...May 2015 Service Manual Part No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE 159 Ground Control Box Layout All Models...

Page 176: ...Service Manual May 2015 160 Ground Control Box Layout All Models...

Page 177: ...May 2015 Service Manual 161 Platform Control Box Layout All Models...

Page 178: ...Service Manual May 2015 162 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 Platform Control Box Layout All Models...

Page 179: ...May 2015 Service Manual Part No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE 163 Generator Wiring Diagram All Models...

Page 180: ...Service Manual May 2015 164 Generator Wiring Diagram All Models...

Page 181: ...May 2015 Service Manual 165 Electrical Schematic GS 2669 BE and GS 3369 BE with 2 Speed Lift ANSI CSA...

Page 182: ...Service Manual May 2015 166 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 Electrical Schematic GS 2669 BE and GS 3369 BE with 2 Speed Lift ANSI CSA...

Page 183: ...May 2015 Service Manual Part No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE 167 Electrical Schematic GS 2669 BE and GS 3369 BE with Proportional Lift ANSI CSA...

Page 184: ...Service Manual May 2015 168 Electrical Schematic GS 2669 BE and GS 3369 BE with Proportional Lift ANSI CSA...

Page 185: ...May 2015 Service Manual 169 Electrical Schematic GS 4069 BE with 2 Speed Lift ANSI CSA...

Page 186: ...Service Manual May 2015 170 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 Electrical Schematic GS 4069 BE with 2 Speed Lift ANSI CSA...

Page 187: ...May 2015 Service Manual Part No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE 171 Electrical Schematic GS 4069 BE with Proportional Lift ANSI CSA...

Page 188: ...Service Manual May 2015 172 Electrical Schematic GS 4069 BE with Proportional Lift ANSI CSA...

Page 189: ...May 2015 Service Manual 173 Electrical Schematic GS 2669 BE and GS 3369 BE with 2 Speed Lift AS CE...

Page 190: ...Service Manual May 2015 174 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 Electrical Schematic GS 2669 BE and GS 3369 BE with 2 Speed Lift AS CE...

Page 191: ...May 2015 Service Manual Part No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE 175 Electrical Schematic GS 2669 BE and GS 3369 BE with Proportional Lift AS CE...

Page 192: ...Service Manual May 2015 176 Electrical Schematic GS 2669 BE and GS 3369 BE with Proportional Lift AS CE...

Page 193: ...May 2015 Service Manual 177 Electrical Schematic GS 4069 BE with 2 Speed Lift AS CE...

Page 194: ...Service Manual May 2015 178 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 Electrical Schematic GS 4069 BE with 2 Speed Lift AS CE...

Page 195: ...May 2015 Service Manual Part No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE 179 Electrical Schematic GS 4069 BE with Proportional Lift AS CE...

Page 196: ...Service Manual May 2015 180 Electrical Schematic GS 4069 BE with Proportional Lift AS CE...

Page 197: ...May 2015 Service Manual 181 Hydraulic Schematic GS 2669 BE and GS 3369 BE with 2 Speed Lift...

Page 198: ...Service Manual May 2015 182 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 Hydraulic Schematic GS 2669 BE and GS 3369 BE with 2 Speed Lift...

Page 199: ...May 2015 Service Manual Part No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE 183 Hydraulic Schematic GS 2669 BE and GS 3369 BE with Proportional Lift...

Page 200: ...Service Manual May 2015 184 Hydraulic Schematic GS 2669 BE and GS 3369 BE with Proportional Lift...

Page 201: ...May 2015 Service Manual 185 Hydraulic Schematic GS 4069 BE with 2 Speed Lift...

Page 202: ...Service Manual May 2015 186 GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 Hydraulic Schematic GS 4069 BE with 2 Speed Lift...

Page 203: ...May 2015 Service Manual Part No 1257106 GS 2669 BE GS 3369 BE GS 4069 BE 187 Hydraulic Schematic GS 4069 BE with Proportional Lift...

Page 204: ...Service Manual May 2015 188 Hydraulic Schematic GS 4069 BE with Proportional Lift GS 2669 BE GS 3369 BE GS 4069 BE Part No 1257106 Service M anual May 2015...

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