Terex Genie GS-2669 DC Service And Repair Manual Download Page 126

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Service and Repair Manual

May 2021

Fault Codes

114

™

-2669 DC • GS

™

-3369 DC • GS

™

-4069 DC

Part No. 1306585GT

Type "CXXX" Faults, continued

DTC

Number

Message on

GCON LCD

Description

Possible Causes

Failure Mode

C034

C034:DCON RR ECM

FAULT TYPE 03

Valve driver failure of the right rear

drive controller.

• Right rear DCON ECM.

Drive functions inhibited.

C035

C034:DCON LR ECM

FAULT TYPE 03

Valve driver failure of the left rear

drive controller.

• Left rear DCON ECM.

Drive functions inhibited.

C036

C036:DCON RR ECM

FAULT TYPE 04

Right rear drive controller voltage

out of range.

• Battery charger connected to AC power source.

• Batteries to low.

• Right rear DCON ECM.

All functions inhibited.

C037

C037:DCON LR ECM

FAULT TYPE 04

Left rear drive controller voltage out

of range.

• Battery charger connected to AC power source.

• Batteries to low.

• Left rear DCON ECM.

All functions inhibited.

C038

C038:DCON RR ECM

FAULT TYPE 05

Capacitor charge failure of the right

rear drive controller.

• Open on B+ or B- to the right rear drive controller.

• Right rear DCON ECM.

All functions inhibited.

C039

C039:DCON LR ECM

FAULT TYPE 05

Capacitior charge failure of the left

rear drive controller.

• Open on B+ or B- to the left rear drive controller.

• Left rear DCON ECM.

All functions inhibited.

C040

C040:DCON RR ECM

FAULT TYPE 06

Open circuit to the PEV (B2) circuit

of the right rear drive controller.

• Open circuit of the right rear motor controller harness.

• Key switch relay CR61 not closed.

• Right rear DCON or GCON ECM.

All functions inhibited.

C041

C041:DCON LR ECM

FAULT TYPE 06

Open circuit to the PEV (B2) circuit

of the LEFT rear drive controller.

• Open circuit of the left rear motor controller harness.

• Key switch relay CR61 not closed.

• Left rear DCON or GCON ECM.

All functions inhibited.

C042

C042:DCON RR ECM

FAULT TYPE 07

Open circuit of the key switch circuit

or battery positive/negative of the

right rear drive controller.

• Open circuit of the right rear motor controller harness.

• Open circuit to B+ and/or B-.

• Key switch relay CR61 not closed.

• 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 circuit of the left rear motor controller harness.

• Open circuit to B+ and/or B-.

• Key switch relay CR61 not closed.

• Left rear DCON or GCON ECM.

All functions inhibited.

C044

C044:DCON RR ECM

FUALT TYPE 08

Communication error of the CAN

circuit between the GCON and the

right rear motor controller.

• Open circuit of the right rear motor controller harness.

• Right rear DCON or GCON ECM.

All functions inhibited.

C045

C045:DCON LR ECM

FAULT TYPE 08

Communication error of the CAN

circuit between the GCON and the

left rear motor controller.

• Open circuit of the left rear motor controller harness.

• Left rear DCON or GCON ECM.

All functions inhibited.

C046

C046:DCON RR ECM

FAULT TYPE 09

Communication error of the CAN

circuit between the GCON and the

right rear motor controller.

• Open or short circuit of the right rear motor controller

harness.

• Right rear DCON or GCON ECM.

All functions inhibited.

C047

C045:DCON LR ECM

FAULT TYPE 09

Communication error of the CAN

circuit between the GCON and the

left rear motor controller.

• Open or short circuit of the left rear motor controller

harness.

• Left rear DCON or GCON ECM.

All functions inhibited.

C048

C048:DCON RR ECM

FAULT TYPE 10

Output error of the thermal sensor

circuit of the right rear motor

controller.

• Right rear DCON ECM.

Performance reduced.

C049

C049:DCON LR ECM

FAULT TYPE 10

Output error of the thermal sensor

circuit of the left rear motor

controller.

• Left rear DCON ECM.

Performance reduced.

C050

C050:SOC MONITOR

NOT DETECTED

State of charge monitor not

detected.

• SOC monitor

• SOC monitor harness

• Incorrect baud rate setting on acuity

• GCON ECM.

Performance reduced.

C053

C053:PCON-GCON

SOFTWARE MISMATCH

Software revisions do not match

between the PCON and GCON.

• C053 displayed at GCON, PCON with older software

revision connected to GCON with newer software revision.

• C053 displayed at PCON, PCON with newer software

revision connected to GCON with older software revision.

All functions inhibited.

Summary of Contents for Genie GS-2669 DC

Page 1: ...S69F 18000 from GS69M 101 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics GS 3369 DC GS 4069 DC For detailed maintenance procedures refer to the appropriate Maintenance Manual for your machine Part No 1306585GT Rev A May 2021 ...

Page 2: ...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...

Page 3: ...istory Revision History Revision Date Section Procedure Page Description A 5 2021 Initial Release Reference Examples Electronic Version Click on any content or procedure in the Table of Contents to view the update Section Repair Procedure 4 2 Section Fault Codes All charts Section Schematics Legends and schematics ...

Page 4: ...r Manual May 2021 Introduction iv GS 2669 DC GS 3369 DC GS 4069 DC Part No 1306585GT Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial label located inside cover 5 Serial number stamped on chassis ...

Page 5: ...identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do not modify or alter a MEWP without prior written permission from the manufacturer Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules a...

Page 6: ...otential 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 Be sure to keep sparks flames and lighted tobacco away...

Page 7: ...y iii Serial Number Legend iv Section 1 Safety Rules v General Safety Rules v Section 2 Specifications 1 Machine Specifications 1 Performance Specifications 1 Hydraulic Oil Specifications 2 Hydraulic Component Specifications 5 Manifold Component Specifications 5 Machine Component Weights 6 Battery Specifications 6 Hydraulic Hose and Fitting Torque Specifications 7 Torque Procedure 8 ...

Page 8: ... 17 2 2 Platform Extension Deck 18 Scissor Components 20 3 1 Scissor Assembly GS 2669 DC 21 3 2 Scissor Assembly GS 3369 DC 24 3 3 Scissor Assembly GS 4069 DC 28 3 4 Wear Pads 31 3 5 Lift Cylinders 33 3 6 Height Angle Sensor 34 How to Replace the Height Angle Sensor 34 Ground Controls 36 4 1 Software Revision Level 37 4 2 Machine Setup 38 4 3 Auxiliary Platform Lowering 39 4 4 Level Sensor Models ...

Page 9: ... 6 2 Valve Adjustments Function Manifold 51 How to Check the System Proportional Relief Valve 51 How to Adjust the Oscillate Relief Valve 52 How to Adjust the Steer Relief Valve 53 How to Adjust the Platform Up Relief Valve 54 6 3 Outrigger Manifold Components 59 6 4 Valve Coils 60 Hydraulic Tank 62 7 1 Hydraulic Tank 62 Steer Axle Components 63 8 1 Yoke Assembly 63 8 2 Steer Cylinder 65 8 3 Tie R...

Page 10: ...s 73 9 1 Drive Motors 73 9 2 Drive Hub 75 Outrigger Components 76 10 1 Outrigger Cylinder 76 10 2 Outrigger Calibration 77 Platform Overload Components 79 How to Calibrate the Platform Overload System 79 11 2 Platform Overload Recovery 81 11 3 Down Limit Height 83 How to Calibrate the Down Limit Height 83 ...

Page 11: ...4 GCON I O Map 87 Control System Fault Codes 89 Platform Overload Fault Codes 94 Operation Indicator Codes OIC 99 Diagnostic Trouble Codes DTC 99 Troubleshooting HXXX and PXXX Faults 100 Fault Inspection Procedure 101 Type HXXX Faults 103 Type PXXX Faults 106 Type UXXX Faults 108 Type FXXX Faults 110 Type CXXX Faults 113 ...

Page 12: ... Color Legends 116 Hydraulic Component Legend 119 Electrical Symbols Legend 120 Hydraulic Symbols Legend 121 Limit Switch Legend 122 Fuse Ground and Platform Control Boxes 123 Fuse Box Layout All Models 124 Ground Control Box Layout 125 Platform Control Box Layout 127 Electrical Schematics 129 Electrical Schematic 130 Hydraulic Schematics 133 Hydraulic Schematic 134 ...

Page 13: ...e 26 x 12D380 Tire ply rating 8 Tire diameter 26 in 66 cm Tire width 12 in 30 cm Weight each 177 5 lbs 80 5 kg For operational specifications refer to the Operator s Manual Performance 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...

Page 14: ... resistant UCON Hydrolube HP 5046 Note Genie specifications require additional equipment and special installation instructions for the approved optional fluids Consult Genie Product Support before use 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 its maximum al...

Page 15: ...ently 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 cSt 104 F 40 C cSt 40 F 40 C 5 5 15 0 510 Flash point 180 F 82 C Pour point 81 F 63 C Maximum continuous operating temperature 124 F 51 C Note Use of Chevron 56...

Page 16: ...82 C Shell Tellus S4 VX Fluid Properties ISO Grade 32 Viscosity index 300 Kinematic Viscosity cSt 200 F 100 C cSt 104 F 40 C 9 33 8 Brookfield Viscosity cSt 4 F 20 C cSt 13 F 25 C cSt 40 F 40 C 481 702 4 2624 Flash point 100 Pour point 76 F 60 C Maximum continuous operating temperature 103 F 75 C UCON Hydrolube HP 5046 Fluid Properties ISO Grade 46 Viscosity index 192 Kinematic Viscosity cSt 149 F...

Page 17: ...alve pressure GS 2669 DC 3100 psi 214 bar Lift relief valve pressure GS 3369 DC 2900 psi 200 bar Lift relief valve pressure GS 4069 DC 2850 psi 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 Manifold Component Specifications Manifold Component Specifications Plug torqu...

Page 18: ...05 battery option 5623 lbs 2551 kg Chassis assembly GS 4069 J305 battery option 7233 lbs 3281 kg Chassis assembly GS 3369 J305 battery option 5309 lbs 2408 kg Chassis assembly GS 2669 J305 battery option 5848 lbs 2653 kg Battery Specifications Battery Specifications T105 Type 6v DC Quantity 8 Capacity 225 AH Reserve capacity 25A rate 447 minutes Reserve capacity 75A rate 115 minutes Weight each 62...

Page 19: ...ts 4 7 16 20 2 6 9 16 18 1 1 2 8 3 4 16 1 1 2 10 7 8 14 1 1 2 12 1 1 16 12 1 1 4 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 ft lbs 31 2 Nm 8 36 ft lbs 49 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 Adjustable Fitting Non ...

Page 20: ...ace seal is seated 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 appropriate torque chart in this section 6 Operate all machine functions and inspect the hose fittings and related components to confirm there are no leaks JIC 37 fittings 1 Align the t...

Page 21: ...e 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 1 body hex fitting 2 reference mark 3 second mark 4 Tighten the hex nut until the mark on the hex nut is aligned with the second mark on the body...

Page 22: ...s 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 shortcuts may produce hazardous conditions Machine Configuration Unless otherwise specified perform each repair procedure with the machine in the following...

Page 23: ...sed 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...

Page 24: ...itch JC9 4 alarm H1 Operational Indicator Codes OIC These codes are generated by the electrical system to indicate machine operating status 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 These codes are not indicators of a device malfunction in the electrical syst...

Page 25: ...th 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 cont...

Page 26: ...ontrol box 5 Remove the ties securing the joystick wire harness 6 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 component...

Page 27: ...e 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 Platfrom Emergency Stop Button 1 4 Platform Emergency Stop Button How to Remove the Platform Controls Emergency Stop Button 1 Push in the red Emergency Stop button to the off position at both the ground and platform controls 2 Dis...

Page 28: ...69 DC GS 3369 DC GS 4069 DC Part No 1306585GT 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 ...

Page 29: ...power to the platform wiring 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 platform Component damage hazard The platform controls wiring can be damaged if it is kinked or pinched 5 Remove the cover from the AC outlet Tag and disconnect the wir...

Page 30: ...ing 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 2 2 Platform Extension Deck 2 2 Platform Extension Deck How to Remove the Platform Extension Deck 1 Remove the retaining fasteners from the deck catch and remove the d...

Page 31: ...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 9 Carefully slide the platform extension out and away from the platform and place it on a structure capable of supporting it Crushing hazard The platfo...

Page 32: ... Number 2 center pivot 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 10Chassis pivot 11Slider block Qty 2 12Number 3 inner arm 13Number 3 center pivot pin Qty 2 14Number 3 pivot pin non steer end 15Number 2 inner arm 16Number 2 outer arm 17Number 2 pivot pin non steer end 18Lift cylinde...

Page 33: ...Remove the cables from 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 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...

Page 34: ... inner arm Make the chains tight but do not apply lifting pressure Crushing hazard The linkage assembly could become unbalanced and fall if not properly supported when removed from the machine 20 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 of the machine until the slider feet are clear...

Page 35: ...ter pivot pin Qty 2 8 Number 2 pivot pin steer end 9 Number 1 outer arm 10Number 1 center pivot pin Qty 2 ANSI CSA 11Number 1 center pivot pin Qty 1 AS CE 12Number 1 inner arm Non steer End 13Chassis pivot 14Slider block Qty 2 15Number 4 inner arm 16Number 4 outer arm 17Number 4 pivot pin non steer end 18Number 3 inner arm 19Number 3 outer arm 20Number 3 pivot pin non steer end 21Number 2 inner ar...

Page 36: ...e the cables from the linkage 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 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 ...

Page 37: ...place it 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 the fittings 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...

Page 38: ...ht 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 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 plac...

Page 39: ... center pivot pin Qty 2 12Number 2 pivot pin steer end 13Number 1 center pivot pin Qty 2 ANSI CSA OR Number 1 center pivot pin Qty 1 AS CE 14Number 1 inner arm 15Chassis pivot Non steer End 16Slider block Qty 2 17Number 5 inner arm 18Number 5 outer arm 19Number 5 pivot pin non steer end 20Upper lift cylinder rod end pivot pin 21Number 4 outer arm 22Number 4 pivot pin non steer end 23Upper lift cyl...

Page 40: ...he cables from the linkage 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 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 mac...

Page 41: ...ce attach 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 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 press...

Page 42: ...zard 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 the linkage assembly off of the machi...

Page 43: ...e lifting device 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 set aside 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 ...

Page 44: ...side 7 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 1 upper wear pads 2 slider foot 3 lower wear pad 10 Install the slider feet into the slider channel and secure them to the linkage assembly with the pivot pins 11 Securely tighten the pivot pi...

Page 45: ...ll 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 GS 3369 DC 1 solenoid valve 2 lift cylinder 3 pressure se...

Page 46: ...placed as a set 1 Start the engine from the ground controls and raise the platform approximately 18 feet 5 5 m from the ground 2 Release the safety arm latch lift the safety arm and rotate to a vertical position Lock the safety arm in position Note Verify the safety arm is locked in the vertical position 3 Lower the platform onto the safety arm Turn the machine off Crushing hazard Keep hands clear...

Page 47: ...able thread locker to the retaining fasteners 7 Remove and replace the angle sensor attached to the angle sensor mount Note The printed side of the sensor must face away from the angle sensor mount Note Apply removable thread locker to the retaining fasteners 8 Install the angle sensor assembly onto the machine Connect the harness 9 Raise the platform and rotate the safety arm to the stowed positi...

Page 48: ...ds 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 available at the ground controls 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 For further information or assistance contact Genie Product Support 1 machine setup escape butt...

Page 49: ...ay at the platform controls 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 Result 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 ...

Page 50: ...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 position and pull out the red Emergency Stop button to the on position at the platform controls 2 Press ...

Page 51: ...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 the front or rear How to Install and Calibrate the Level Sensor Tip over hazard Failure to install or calibrate the level sensor as instructed will compromise machine stability and cause the machine to tip over resulting in death or se...

Page 52: ...ners Tip 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 machine tipping over causing death or serious injury 1 Y indicator 2 level sensor 3 X indicator 4 chassis 6 Connect the wire harness to the level sensor 7 Adjust the level sensor retaining fa...

Page 53: ...the machine approximately 4 inches 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 approximately 4 inches 10 cm 21 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 22 Lower the ...

Page 54: ...ine of the chassis exceeds 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 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 mac...

Page 55: ...e towards 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 X indicator 6 Connect the wire harness to the level sensor 7 Adjust the level sensor retaining fasteners until the bubble in the top of the level sensor is centered in the circles Note Be sure...

Page 56: ...ecting 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 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...

Page 57: ...the ground 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 show the following 7 Press the enter button Result The ground controls LCD display will show the following ...

Page 58: ...om 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 How to Remove the Hydraulic Pump How to Remove the Hydraulic Pump 1 Tag disconnect and plug the hydraulic hoses on the pump Cap the fittings on the p...

Page 59: ... down 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 Scroll Up and Scroll Down buttons after the ground controller powers up 5 At the ground controls use the Scroll Up or Scroll Down buttons to scroll to Select Option 6 Press the Enter button 7 Use t...

Page 60: ...tton until 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 Note The screen will return to the options screen after 2 seconds Result The ground controls LCD displays the following screen Calibration data is not within range The pump needs to be repaired o...

Page 61: ...25 ft lbs Nm 6 Relief valve 1500 psi 103 bar FI Steer circuit 20 ft lbs 27 Nm 7 Check valve FJ Load sense 20 ft lbs 27 Nm 8 Flow control valve 2 gpm 7 6 L min FK Controls flow to the steer circuit 20 ft lbs 27 Nm 9 Solenoid valve 3 position 5 way FL Steer circuit 20 ft lbs 27 Nm Check valve FM 10 Flow control valve 1 gpm 3 8 L min FG Controls flow to the oscillate circuit 20 ft lbs 27 Nm 11 Soleno...

Page 62: ...Service and Repair Manual May 2021 Manifolds 50 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1306585GT ...

Page 63: ...ntrols 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...

Page 64: ...ey switch to platform control and pull out the red Emergency Stop button to the on position at both the ground and platform controls 6 Steer the machine to the right and hold Note the pressure readings on the pressure gauge Refer to Specifications Hydraulic Components Specifications 7 Use a wrench to hold the oscillate relief valve and remove the cap 8 Adjust the internal hex socket Turn it clockw...

Page 65: ...l and pull out the red Emergency Stop button to the on position at both the ground and platform controls 5 Steer the machine fully to the right or left and hold Note the pressure reading on the pressure gauge Refer to Specifications Hydraulic Components Specifications 6 Use a wrench to hold the steer relief valve and remove the cap 7 Adjust the internal hex socket Turn it clockwise to increase the...

Page 66: ... 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 and hold the ground control scroll up and scroll down buttons Ground Control Menu Buttons 1 scroll down button 2 enter button 3 scroll down button 4 escape button 5 LCD display 4 Pull out the red Emergency Stop button to th...

Page 67: ...After 1 second the display will return to SELECT OPTION PLAT OVERLOAD 10 Press the Scroll Down button to scroll to Down Delay Result The ground controls LCD display will show the following 11 Press the enter button Result The ground controls LCD display will show the following 12 Press the enter button Result The ground controls LCD display will show the following Note After 1 second the display w...

Page 68: ... the cap 25 Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap 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 26 Repeat this procedure begin...

Page 69: ... Result The ground controls LCD display will show the following 42 Press the enter button Result The ground controls LCD display will show the following 43 Press the enter button Result The ground controls LCD display will show the following 44 Press the enter button Result The ground controls LCD display will show the following Note After 1 second the display will return to SELECT OPTION PLAT OVE...

Page 70: ...The ground controls LCD display will show the following Note After 1 second the display will return to SELECT OPTION DOWN DELAY 48 Push in the red Emergency Stop button to the off position 49 Test the platform overload system Refer to the appropriate Maintenance Manual and procedure for your machine Test the Platform overload System ...

Page 71: ... DC GS 4069 DC 59 6 3 Outrigger Manifold Components 6 3 Outrigger Manifold Components The outrigger manifold is located inside the hydraulic compartment Index No Description Schematic Item Function Torque 1 Solenoid valve 3 position 4 way BA Outriggers extend retract 40 ft lbs 54 Nm ...

Page 72: ...ould result in 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 the wiring from the coil to be tested 2 Test the coil resistance using a multimeter set to resistance Ω Refer to the Valve Coil Resistance Specification table Result If the resistance is ...

Page 73: ...erminal on the coil Resistor 10Ω 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 10Ω resistor 4 coil Note Dotted lines in illustration indicate a reversed connection as specified in step 6 3 Set a multimeter to read DC current Note The multimeter when set to read DC current should be capable of reading up to 800 m...

Page 74: ... Hose and Fitting Torque 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 Specifications 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 ...

Page 75: ...support 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 Left side yoke 7 Remove the retaining fasteners from the tie rod pivot pin 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 ...

Page 76: ...ing 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 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 How to Remove a Drive Motor Component damage hazard Repairs to the motor should only be performed by a...

Page 77: ...e oil pressure 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 8 3 Tie Rod 8 3 Tie Rod How to Remove the Tie Rod 1 Remove the rue ring from the clevis pin connecting the tie rod to the right side yoke assembly Remove the clevis pin 1 clevis pin 2 pivot pin 3 steer sens...

Page 78: ...n 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 dr...

Page 79: ...t both the ground and platform controls 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 7 Turn the key switch to the off position 8 Swap the connectors back to the correct coils using steps 2 an 3 as a reference ...

Page 80: ...ion 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 switch to the off position 4 Remove the cable clamp securing the steer sensor cable to the chassis 5 Tag and disconnect the steer sensor harness from the main harness 6 Remove the steer sensor cover 7 Remove the tie rod pivot pin retain...

Page 81: ...ll the steer sensor assembly to the yoke 16 Rotate the tie rod pivot pin until it is approximately 90 from the mounting tab on the tie rod 17 Install the steer sensor actuator onto the tie rod pivot 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 enga...

Page 82: ... 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 Scroll Up and Scroll Down buttons after the ground controller powers up 5 At the ground controls use the Scroll Down button to scroll to SELECT OPTION 6 Press the enter button 7 Use the Scroll Up or Scroll Down buttons to scroll to Select Option Steer Se...

Page 83: ...und controls 11 Press the enter button Result The ground controls LCD display will show the following 12 Use the platform drive controller steer function to align the steer tires with the drive chassis 13 Press the enter button Result The ground controls LCD display will show the following 14 Use the platform drive controller steer function to turn the steer tires fully to the right 15 Press the e...

Page 84: ...steer function to turn the steer tires fully to the left 17 Press the enter button Result The ground controls LCD display will show the following Note If any screens other than the one shown is displayed repeat this procedure If the problem persist contact your local Genie Product Support 18 Push in the red Emergency Stop button to the off position ...

Page 85: ... 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 Crushing hazard The chassis will fall if not properly supported 6 Remove the...

Page 86: ...taining 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 14 Remove the retaining fasteners that secure the drive motor to the drive hub 15 Support and slide the drive motor shaft out of the drive hub Remove the ...

Page 87: ...suitable supporting 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 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 ...

Page 88: ...r Remove the cover 5 Tag disconnect 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 very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 6 Attach a lifting strap from an overhead crane to the barrel end of the out...

Page 89: ...ion or assistance contact Genie Product Support How to Calibrate the Outrigger System 1 Move the machine to an area that has a firm level surface and is free of obstructions 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 and hold the ground control scroll up and scroll down buttons 1 scroll down b...

Page 90: ...gger movement 13 Continue holding the Enter button after the outrigger level sensor is calibrated The outriggers will retract while the outrigger system gathers and saves data 14 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 15 Continue holding the Enter button after the outriggers ...

Page 91: ... all weight tools and equipment removed from the platform Note Perform this procedure in an area that is free of overhead obstructions 1 Models with outriggers Fully lower the outriggers and level the machine 2 Using a suitable lifting device place and secure the maximum rated load in the center of the platform deck Model Maximum rated load GS 2669 1500 lbs 680 kg GS 3369 1000 lbs 454 kg GS 4069 8...

Page 92: ...the platform has reached full height momentarily activate the calibration toggle switch in the up position to confirm 12 Fully lower the platform to the stowed position Note The platform will lower and automatically stop at predetermined points to gather data Continue holding the Function Enable and Platform Down buttons until the platform is fully stowed 13 When the platform is fully stowed momen...

Page 93: ...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 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 3 Pull out the red Emergency Stop button at the ground controls...

Page 94: ...lowing 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 appear on the second line of the LCD display Result The ground control LCD display will show the following Note After 3 seconds the LCD display will return to SELECT OPTION PLAT OVERLOAD 10 Push in ...

Page 95: ... audible alarm is heard 4 Raise the platform until it stops 5 Push in the red Emergency Stop button to the off position 6 Measure the distance between the surface and the platform floor Model Measurement GS 2669 64 76 inches 163 193 cm GS 3369 66 78 inches 168 198 cm GS 4069 74 86 inches 188 218 cm Result Platform height is within range Adjustment not required Result Platform height is not within ...

Page 96: ... 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 Crushi...

Page 97: ...martLink 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 The diagnostic readout displays alpha numeric codes that provide information about the machine operating status and about malfunctions The codes listed in the Diagnostic Trouble Code Chart...

Page 98: ...dicator 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 GCON ECM Connector Layout Rear of Grou...

Page 99: ...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 ...

Page 100: ...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 S...

Page 101: ...out The diagnostic readout displays numerical codes that provide information about the machine operating status and about malfunctions The dot to the right of the numbers remain on when a fault code is displayed The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the area or component affected ...

Page 102: ...FT TURN SW FAULT Red Left turn switch fault Malfunctioning steer left microswitch Troubleshoot steer left microswitch 26 RIGHT TURN SW FAULT Red Right turn switch fault Malfunctioning steer right microswitch Troubleshoot steer right microswitch 27 DRIVE ENABLE SW FLT Red Function enable switch on joystick is activated when machine is turned on Machine functions disabled Release function enable swi...

Page 103: ...evel enable button fault at platform controls Outriggers disabled Troubleshoot button OR replace printed circuit board at platform controls 3812 OSCILLATE LIMIT SWITCHES Red Value to high Voltage above 3000 mV Elevated drive and platform up disabled Troubleshoot oscillate limit switches 3815 OSCILLATE LIMIT SWITCHES Red Value to low Voltage below 1000 mV Elevated drive and platform up disabled Tro...

Page 104: ...on inhibited Troubleshoot coil OR wiring 58 BRAKE COIL FAULT Red Brake release coil Y2 fault Brakes will not release Troubleshoot coil OR wiring 60 FORWARD 1 COIL FAULT Red Forward 1 coil Y6 fault Drives slow or not at all when elevated Troubleshoot coil OR wiring 61 REVERSE 1 COIL FAULT Red Reverse 1 coil Y5 fault Drives slow or not at all when elevated Troubleshoot coil OR wiring 62 FORWARD 2 CO...

Page 105: ...ng 82 RIGHT FRONT OTRG COIL FLT Red Right front outrigger coil Y36 fault Right front outrigger function inhibited Troubleshoot coil OR wiring 83 RIGHT REAR OTRG COIL FLT Red Right rear outrigger coil Y34 fault Right rear outrigger function inhibited Troubleshoot coil OR wiring 84 OUTRIGGER EXT COIL FLT Red Outrigger extend coil Y40 fault Outrigger extend function disabled Troubleshoot coil OR wiri...

Page 106: ...oad Fault Codes Platform Overload Display 1 LCD screen 2 red LED The diagnostic readout displays numerical codes that provide information about height sensor pressure sensor and platform overload malfunctions The codes listed in the Fault Code Chart can aid in troubleshooting the machine by pinpointing the area or component affected ...

Page 107: ...ing consistent or correlated signals Check wiring Shorted to high or low Replace sensor 15 Value too low Output lower than normal Check wiring Check 5V supply voltage Check ground Open or short circuit Replace sensor 16 Value at 0 V Output at 0 volts Check wiring Open circuit Replace sensor Replace SCON 23 Too high Outputs higher than calibration point Check height sensor for loose or missing fast...

Page 108: ... too high Replace sensor 15 Value too low Output lower than normal Check wiring Check 5V supply voltage Check ground Open or short circuit Replace sensor 16 Value at 0 V Output at 0 volts Check wiring Open circuit Replace sensor Replace SCON 23 Too high Outputs higher than calibration point Check height sensor for loose or missing fasteners Calibrate Sensor 24 Too low Outputs lower than calibratio...

Page 109: ... high or low Replace sensor 15 Value too low Output lower than normal Check wiring Check 5V supply voltage Check ground Open or short circuit Replace sensor 16 Value at 0 V Output at 0 volts Check wiring Open circuit Replace sensor Replace SCON 215 Pressure sensor Safety 12 Value too high Output higher than normal Check wiring Check 5V supply voltage Shorted too high Replace sensor 15 Value too lo...

Page 110: ... Software version mismatch Primary and secondary processors software do not match Update software Replace SCON 76 Platform Overload 23 Too high Platform overloaded Remove weight from platform 79 DISCON Display controller 13 Not detected No communication between SCON and platform overload display DISCON Check wiring Check SCON connections Check GCON connections Replace SCON Replace DISCON ...

Page 111: ...attery 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 Exam...

Page 112: ...it of the harness or connector 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 shown below illustrates how fault type HXXX and PXXX devices are typically wired The signal of these types of devices originates at the Ground Controls and terminates at syst...

Page 113: ...utomotive Horn 1 0 Ω Contactor Coil 47 Ω 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 equipped with outriggers 2 Disconnect the faulted device connector 3 Check the continuity between the GCON ECM connector and the signal side of the faulted device Result Resistance s...

Page 114: ...CON pin 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 Ω 4 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 5 Short to p...

Page 115: ...tform down H049 H049 COILFAULT 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 Outrigger extend function disabled H050 H050 COIL FAULT O R EXTEND Open Open circuit in the outrigger extend coil circuit Open circuit in outrigger extend coil harness Outrigger extend coil open circ...

Page 116: ... the steer 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 RIGHT Short circuit of the steer right circuit to battery negative or open circuit Short or open circuit in steer right harness Steer right coil short or open circuit GCON ECM Steer right funct...

Page 117: ...H092 H092 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 in the elevated position If machine is in stowed position all functionality is resumed H093 H093 COILFAULT ACCUM Bat Short circuit of the accumulator circuit to battery positive Short circuit ...

Page 118: ... power return harness 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 inhibited P019 P019 PWRFAULT PCON POWER Bat Short circuit of the PCON power circuit to battery positive Short circuit in PCON power harness GCON ECM All functions inhibited P023 P023 PUMPMOTOR...

Page 119: ...t rear brake harness Short circuit in left rear brake coil Left rear brake harness miswired Left rear DCON ECM All functions inhibited P037 P037 BATTERY OUT OF RANGE Battery voltage is out of range at startup Short or open circuit in voltage sensor circuits Low batteries Faulty battery Battery charger connected to AC power source Left or right DCON ECM All functions inhibited P038 P038 DEVICEFAULT...

Page 120: ... All GCON LCD menu 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 menu functions inhibited U006 U006 SWITCHFAULT GCON LCD ENTER Short circuit of the GCON LCD enter switch at system startup Short circuit of the GCON LCD enter switch GCON ECM All GCON LCD...

Page 121: ...nable switch 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 circuit in PCON power harness Enable switch shorted battery positive PCON ECM All drive and steer functions inhibited U039 U039 SWITCHFAULT FOOTSW Open Bat Open or short circuit of the PCON power c...

Page 122: ... functions inhibited F037 F037 SWITCHFAULT LF RIGGER Bat Short circuit of the left front outrigger limit switch to battery positive 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 retracted F039 F039 SWITCHFAULT RF RIGGER Bat Short circuit of the right front out...

Page 123: ...to 221 F 105 C Drive 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 drive motor encoder Faulty encoder in right rear drive motor Faulty right rear drive motor Right rear DCON ECM All functions inhibited F058 F058 MOTOR LR ENCODER FAULT Return signal fr...

Page 124: ...fety or operational limit switch Right rear DCON or GCON ECM All functions inhibited except platform as long as machine is in the elevated position If machine is in stowed position all functionality is resumed F069 F069 SWITCHFAULT OSC LIM SWITCHES Right and left axle safety or operational limit switches are in an open state Open circuit of the right and or left axle safety or operational limit sw...

Page 125: ... Discrepancy between model detected and model programmed Incorrect machine model programmed 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 C028 C028 SERVICE OVERRIDE MODE ON Machine is in service override mode Machine programmed for use in service...

Page 126: ...ey switch relay CR61 not closed 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 circuit of the left rear motor controller harness Open circuit to B and or B Key switch relay CR61 not closed Left rear DCON or GCON ECM All functions inhibited C044 C044 DC...

Page 127: ...and 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 About This Section There are two groups of schematics in this section Electrical Schematics Electrocution burn hazard Contact with electrically charged circuits could result in death or serious injury Remov...

Page 128: ...O H C Normally open held closed N C H O Normally closed held open F Fuse F9 50 amp 800W inverter option F27 30 amp 48V DC battery charger F28 5 amp 24V DC battery balancer F29 5 amp 48V DC battery balancer FB Flashing beacon FB1 Option G Gauge G8 Diagnostic display H Horn or alarm H2 Horn H5 Multi function alarm ground H8 Alarm platform JC Hall effect controller JC3 Drive Steer KS Key switch KS1 K...

Page 129: ...ggle switch TS10 Auxiliary down ground TS51 Auxiliary down enable ground U Electronic Component U1 GCON smartlink ground U2 PCON smartlink platform U3A Right DCON U3B Left DCON U4 Battery charger U5 Battery Balancer U6 800W inverter option U7 SC050 U8 CAN display U9 PSI transducer U10 Angle sensor Y Valve coil Y3 Steer right CW Y4 Steer left CCW Y5 Drive reverse Y7 Platform down Y7A Platform down ...

Page 130: ...9 DC Part No 1306585GT Wire Color Legend Color Description BL Blue BK Black BR Brown GR Green 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 ...

Page 131: ...er option 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 2 way valve oscillate supply FG Flow regulator valve controls flow to the oscillate Item Function FH Relief valve main system FI Relief valve steer circuit FJ Check valve load sense circ...

Page 132: ...h suppression LED Fuse 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 Contact solenoid or relay Button normally open Limit switch not held Limit switch held Red emergency stop button normally closed Resistor with ohm value Starting aid or glow plug Electr...

Page 133: ...regulator Needle valve Solenoid operated 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 Filter with bypass relief valve Relief valve with pressure setting Solenoid operated proportional valve Differential sensing valve Pilot operated flow regulator valv...

Page 134: ...5GT Limit Switch Legend 1 left rear outrigger limit switch LS14 2 left axle oscillate limit switches LSA10S and LSA10SS 3 right rear outrigger limit switch LS15 4 right axle oscillate limit switches LSA20S and LSA20SS 5 right front outrigger limit switch LS13 left front outrigger limit switch LS12 not shown ...

Page 135: ...May 2021 Service and Repair Manual 123 use Ground and Platform Control Boxes Fuse Box Layout All Models ...

Page 136: ...Service and Repair Manual May 2021 124 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1306585GT Fuse Box Layout All Models Fuse Box Layout All Models ...

Page 137: ...2 CR61 CR60 U1 FRONT U1 BACK C2 C1 C3 XXXXXX GCON GS69 SOFTWARE XXXXXX XXXXXX C2 C4 C1 C3 XXXXXX GCON GS69 SOFTWARE XXXXXX XXXXXX MODELS WITHOUT OUTRIGGERS U1 BACK MODELS WITH OUTRIGGERS TERMINAL BASE TB 1 2 3 1 2 3 4 5 6 7 8 A B C D E F G H I J K L M 1 2 3 4 5 6 7 8 C 78 R C 77 R KS1 P1 CB2 CB7 H5 B 33 N B 34 N B 35 N B 108 N B 109 N B 110 N B 111 N U1 TS51 TS10 G8 S 1 W ...

Page 138: ...Service and Repair Manual May 2021 126 Ground Control Box Layout ...

Page 139: ...May 2021 Service and Repair Manual Part No 1306585GT GS 2669 DC GS 3369 DC GS 4069 DC 127 Platform Control Box Layout Platform Control Box Layout ...

Page 140: ...Service and Repair Manual May 2021 128 Platform Control Box Layout ...

Page 141: ...May 2021 Service and Repair Manual 129 Electrical Schematics Electrical Schematic ...

Page 142: ...NK PCON DCON LEFT AC MOTOR CONTROLLER C134PWR RD C134LO RD ENCODER BRAKE JOY X AXIS N C AI GND GND ENAB SW L STEER R STEER 5V N C V SNSR GND N C GND 01 02 03 04 05 06 07 08 09 10 11 12 2K OHM EN POWER TO PLATFORM AC POWER C38 C39 1 2 3 4 5 C6 C7 1 2 GND BN P110RET BK C134PWR RD V101RO WH BK V100EO WH RD V203RR GR WH V202LR BL WH V201RF OR WH V200LF BK WH C84ANG GR BK C83ANG GR WH C207RR GR C206LR ...

Page 143: ... D82CAN YL D81CAN GR D82CAN YL D81CAN GR SC050 1 GND 2 V 3 CAN 0 4 CAN 0 7 CALIBRATE 8 5V 9 SNSR GROUND 11 C134PWR MONITOR 12 ANGLE SENSOR 1 13 ANGLE SENSOR 2 18 PSI SENSOR 1 19 PSI SENSOR 2 20 CAN 1 21 CAN 1 23 DWN COIL MONITOR 24 UP COIL MONITOR 33 UP INT RELAY 34 DWN INT RELAY 35 UP LIM SW 36 DWN LIM SW 37 DWN LIM SW 39 OVERLOAD NC 40 OVERLOAD NO 47 V 48 V 49 V 50 V D82CAN YL D81CAN GR R2 51 R3...

Page 144: ...Service and Repair Manual May 2021 132 Electrical Schematic ...

Page 145: ...May 2021 Service and Repair Manual 133 Hydraulic Schematics Hydraulic Schematic ...

Page 146: ...TE FLOWS ARE CALCULATED AT 3100 RPM GS 4069 2 850 PSI RV7 CYLINDER HIGH PRESSURE FILTER Y39 Y40 T SV18 375 C C 375 C C RIGHT FRONT LEFT FRONT B B A A ORF1 Ø 030 TP1 PUMP PS TP2 OSC L S2 1500 PSI SV2 3300 3500 RV3 RV2 1 GPM FR1 SV4 SV5 FR2 2 GPM TS1 RV4 SV6 SV3 SV1 CV1 CV2 CV3 TANK OSC R ACCUM S1 O R L SV10 SV9 SV8 RV6 3500 PSI PSI 3500 RV5 Ø 060 50 50 FD1 FOUR WHEEL DRIVE OPTION P IN T OUT LFA LFB...

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