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Service and Repair Manual

November 2016

Fault Codes

102

GS-2669 DC • GS-3369 DC • GS-4069 DC

Part No. 1272220GT

Type "HXXX" Faults

Type "HXXX" Faults

DTC

Number

Message on

GCON LCD

Description

Possible Causes

Failure Mode

H001

H001:COILFAULT
PLAT UP1:Bat-

Short circuit of the platform up #1
circuit to battery negative.

• Short circuit in platform up #1 harness.
• Platform up #1 coil short circuit.
• GCON ECM.

Platform up function
inhibited.

H002

H002:COILFAULT
PLAT UP1:Open

Open circuit in the platform up #1
circuit.

• Short circuit in platform up #1 harness.
• Platform up #1 coil short circuit.
• GCON ECM.

Platform up function
inhibited.

H003

H003:COILFAULT
PLAT UP1:Bat+

Short circuit of the platform up #1
circuit to battery positive.

• Short circuit in platform up #1 harness.
• Platform up #1 coil short circuit.
• GCON ECM.

All functions inhibited
except platform down.

H009

H009:COILFAULT
PLAT DOWN1:Bat+

Short circuit of the platform down #1
circuit to battery positive.

• Short circuit in platform down #1 harness.
• Platform down #1 coil short circuit.
• GCON ECM.

All functions inhibited.

H027

H027:COILFAULT
STEER RT:Bat+

Short circuit of the steer right circuit to
battery positive.

• Short circuit in steer right harness.
• Steer right coil short circuit.
• GCON ECM.

All functions inhibited
except platform down.

H030

H030:COILFAULT
STEER LT:Bat+

Short circuit of the steer left circuit to
battery positive.

• Short circuit in steer left harness.
• Steer left coil short circuit.
• GCON ECM.

All functions inhibited
except platform down.

H043

H043:COIL FAULT
BRAKE REL:Bat-

Short circuit of the brake circuit to
battery negative.

• Short circuit in brake release enable harness.
• Brake release relay short circuit.
• GCON ECM.

All functions inhibited
except platform down.

H045

H045:COILFAULT
BRAKE REL:Bat+

Short circuit of the brake circuit to
battery positive.

• Short circuit in brake release enable harness.
• Brake release relay short circuit.
• GCON ECM.

All functions inhibited
except platform down.

H049

H049:COILFAULT
O/R EXTEND:Bat-

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 circuit.
• GCON ECM.

Outrigger extend function
disabled.

H051

H051:COILFAULT
O/R EXTEND:Bat+

Short circuit of the outrigger extend
coil to battery positive.

• Short circuit in outrigger extend coil harness.
• Outrigger extend coil short circuit.
• GCON ECM.

All functions inhibited
except platform down.

H052

H052:COILFAULT
O/R RETRACT:Bat-

Short circuit of the outrigger retract coil
to battery negative.

• Short circuit in outrigger retract coil harness.
• Outrigger retract coil short circuit.
• GCON ECM.

Outrigger retract function
disabled.

H053

H053:COILFAULT
O/R RET:Open

Open circuit in the outrigger retract coil
circuit.

• Open circuit in outrigger retract coil harness.
• Outrigger retract coil open circuit.
• GCON ECM.

Outrigger retract function
disabled.

H054

H054:COILFAULT
O/R RETRACT:Bat+

Short circuit of the outrigger retract coil
to battery positive.

• Short circuit in outrigger retract coil harness.
• Outrigger retract coil short circuit.
• GCON ECM.

All functions inhibited
except platform down.

H057

H057:COILFAULT
LF RIGGER:Bat+

Short circuit of the left front outrigger
coil to battery positive.

• Short circuit in left front outrigger coil harness.
• Left front outrigger coil short circuit.
• GCON ECM.

All functions inhibited
except platform down.

H060

H060:COILFAULT
LR RIGGER:Bat+

Short circuit of the left rear outrigger
coil to battery positive.

• Short circuit in left rear outrigger coil harness.
• Left rear outrigger coil short circuit.
• GCON ECM.

All functions inhibited
except platform down.

H063

H063:COILFAULT
RF RIGGER:Bat+

Short circuit of the right front outrigger
coil to battery positive.

• Short circuit in right front outrigger coil harness.
• Right front outrigger coil short circuit.
• GCON ECM.

All functions inhibited
except platform down.

Содержание GS-2669 DC

Страница 1: ...F 7897to GS6916F 10499 This manual includes Repair procedures Fault Codes Electrical and Hydraulic Schematics GS 3369 DC GS 4069 DC From GS69F 10500 For detailed maintenance procedures refer to the ap...

Страница 2: ...ISO 16368 Machine Design Life Unrestricted with proper operation inspection and scheduled maintenance Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible How...

Страница 3: ...1 9 2016 Introduction Serial Number Legend A2 11 2016 Repair Function manifold with proportional relief A2 11 2016 Schematics Hydraulic and Electrical add proportional relief circuit Reference Example...

Страница 4: ...0GT Serial Number Legend To August 31 2016 1 Model 2 Model year 3 Facility code 4 Sequence number 5 Serial label located inside cover 6 Serial number stamped on chassis From September 1 2016 1 Model 2...

Страница 5: ...death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are...

Страница 6: ...potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Any person working on or arou...

Страница 7: ...Component Specifications 4 Manifold Component Specifications 4 Battery Specifications 4 Hydraulic Hose and Fitting Torque Specifications 5 Torque Procedure 6 Section 3 Repair Procedures 8 Introductio...

Страница 8: ...42 How to Remove the Hydraulic Pump 42 How to Calibrate the Hydraulic Pump 43 Manifolds 45 6 1 Function Manifold Components 45 6 1a Function Manifold Components 46 6 2 Valve Adjustments Function Mani...

Страница 9: ...2 Drive Hub 83 Outrigger Components 84 10 1 Outrigger Cylinder 84 10 2 Outrigger Calibration 85 Platform Overload Components 87 11 1 Platform Overload System 87 11 2 Platform Overload Recovery 91 Sec...

Страница 10: ...portional Lift 129 Electrical Schematics ANSI CSA 131 Electrical Schematic GS 2669 DC and GS 3369 DC with 2 Speed Lift ANSI CSA to serial number GS6915 6388 132 Electrical Schematic GS 2669 DC and GS...

Страница 11: ...DC with Proportional Lift AS CE from serial number GS6915 6389 to GS6915 7719 152 Electrical Schematic GS 4069 DC with Proportional Lift AS CE from serial number GS6915 7720 153 Hydraulic Schematics...

Страница 12: ...ize 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 Specificati o...

Страница 13: ...Fire 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...

Страница 14: ...e Use of Chevron 5606A hydraulic fluid or equivalent is required when ambient temperatures are consistently below 0 F 17 C unless an oil heating system is used Continued use of Chevron 5606A hydraulic...

Страница 15: ...lief valve pressure 3300 psi 228 bar Steer flow regulator 2 gpm 7 6 L min Oscillate flow regulator 1 gpm 4 L min Manifold Com ponent Specificati ons Manifold Component Specifications Plug torque SAE N...

Страница 16: ...read Size Flats 4 7 16 20 2 6 9 16 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 Si...

Страница 17: ...face 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 tor...

Страница 18: ...the correct number of flats for the proper tightening position Note The marks indicate the correct tightening positions have been determined Use the second mark on the body hex fitting to properly tig...

Страница 19: ...ons 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 comple...

Страница 20: ...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...

Страница 21: ...9 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...

Страница 22: ...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 boa...

Страница 23: ...control 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 elect...

Страница 24: ...6 Carefully remove the alarm from the platform control box 1 4 Platfrom Em ergency Stop Button 1 4 Platform Emergency Stop Button How to Remove the Platform Controls Emergency Stop Button 1 Push in th...

Страница 25: ...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 Remov...

Страница 26: ...hing 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 the...

Страница 27: ...m 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 t...

Страница 28: ...mber 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 10 Chassis pivot 11 S...

Страница 29: ...3 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...

Страница 30: ...1 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 Re...

Страница 31: ...ot pin Qty 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 piv...

Страница 32: ...ove 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 end...

Страница 33: ...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 a...

Страница 34: ...ght 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 fro...

Страница 35: ...pivot pin 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 blo...

Страница 36: ...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...

Страница 37: ...vice 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...

Страница 38: ...azard 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...

Страница 39: ...ble 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 t...

Страница 40: ...aside 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 sl...

Страница 41: ...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...

Страница 42: ...S 3369 DC GS 4069 DC 31 2 Disassemble the scissor assembly Refer to Repair Procedure How to Disassemble the Scissor Assembly GS 4069 DC 1 solenoid valve proportional lift models 2 solenoid valve 2 spe...

Страница 43: ...nds 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 mo...

Страница 44: ...splay 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 cont...

Страница 45: ...y 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 t...

Страница 46: ...ve 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...

Страница 47: ...eners 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 resu...

Страница 48: ...ly 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 m...

Страница 49: ...cline 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 sta...

Страница 50: ...ase 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 in...

Страница 51: ...fecting 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...

Страница 52: ...t 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 displa...

Страница 53: ...from the platform and place the controls near the function manifold on the tank side of the machine 3 Steer the machine fully to the right or left and hold Note the pressure reading on the pressure g...

Страница 54: ...oll 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 Releas...

Страница 55: ...utton 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...

Страница 56: ...ition 3 way FF Oscillate circuit 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 l...

Страница 57: ...Service and Repair Manual November 2016 Manifolds 46 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1272220GT 6 1a Function M ani fol d C omponents...

Страница 58: ...Nm 100 3500 psi 7 241 bar 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 stee...

Страница 59: ...Service and Repair Manual November 2016 Manifolds 48 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1272220GT...

Страница 60: ...atform 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 cont...

Страница 61: ...nction 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 ou...

Страница 62: ...l out the 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 Spec...

Страница 63: ...d pull out the 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...

Страница 64: ...latform control 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...

Страница 65: ...tform control 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 o...

Страница 66: ...e function 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 control...

Страница 67: ...the Enter 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...

Страница 68: ...the red 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 l...

Страница 69: ...gher than specifications 28 Repeat this procedure beginning with step 24 to confirm the relief valve pressure 29 Lower the platform to the stowed position 30 Remove the weight from the platform 31 Rai...

Страница 70: ...s LCD display 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 sho...

Страница 71: ...ce Procedures Test the Platform overload System and Down Limit Switch Decent delay How to Adjust the Platform Up Relief Valve Models with Platform Overload and Proportional Relief Note Verify the hydr...

Страница 72: ...p 6 At the ground controls use the Scroll Down button to scroll to SELECT OPTION Result The ground controls LCD display will show the following 7 Press the Enter button Result The ground controls LCD...

Страница 73: ...ortional lift models 2 solenoid valve 2 speed lift models 3 lift cylinder 4 pressure switch AS CE models 19 Locate and disconnect the maximum height limit switch harness 1 maximum height limit switch...

Страница 74: ...ximately 10 feet 3 m 31 Lift the safety arm move it to the center of the scissor arm and rotate down to a vertical position 32 Lower the platform onto the safety arm 33 Push in the red Emergency Stop...

Страница 75: ...d the display will return to SELECT OPTION PLAT OVERLOAD 47 Press the Scroll Down button to scroll to Down Delay Result The ground controls LCD display will show the following 48 Press the Enter butto...

Страница 76: ...lift function enable button and platform up button Allow the platform to raise completely then continue activating the lift function while observing the pressure reading on the pressure gauge Note th...

Страница 77: ...and platform up button Allow the platform to raise completely then continue activating the lift function while observing the pressure reading on the pressure gauge Note the pressure Refer to Specific...

Страница 78: ...DC GS 4069 DC 67 6 3 Outrigger M anifol d C omponents 6 3 Outrigger Manifold Components The outrigger manifold is located inside the hydraulic compartment Index No Description Schematic Item Function...

Страница 79: ...ts could 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 Ta...

Страница 80: ...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 9v DC battery 3 10 resistor 4 coil Note Dotted l...

Страница 81: ...lic 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...

Страница 82: ...pport 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 L...

Страница 83: ...ning 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...

Страница 84: ...he 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 T...

Страница 85: ...kin 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...

Страница 86: ...at 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 r...

Страница 87: ...he steer tires so they 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...

Страница 88: ...teer sensor 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 retaini...

Страница 89: ...nstall the steer sensor cover 21 Connect the steer sensor harness to the main harness and secure with the cable clamp 22 Calibrate the steer sensor Refer to Repair Procedure How to Calibrate the Steer...

Страница 90: ...r button 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 bu...

Страница 91: ...o the right 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 Pr...

Страница 92: ...ve 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...

Страница 93: ...etaining 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 dr...

Страница 94: ...a 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...

Страница 95: ...over 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...

Страница 96: ...ation 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...

Страница 97: ...rigger 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 th...

Страница 98: ...lb 363 kg 4 Turn the key switch to ground controls and pull out the red Emergency Stop button to the on position at both ground and platform controls 5 Raise the platform approximately 10 feet 3 m 6 L...

Страница 99: ...rm to the stowed position Check the Maximum Height Limit Switch 1 Using a suitable lifting device place a test weight in the center of the platform floor Secure the weight to the platform Refer to the...

Страница 100: ...Overload Components Part No 1272220GT GS 2669 DC GS 3369 DC GS 4069 DC 89 8 Lower the platform to the stowed position Remove the test weight Limit switch legend 1 down limit switch 2 load sense inter...

Страница 101: ...ch 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 Charge batterie...

Страница 102: ...g 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 r...

Страница 103: ...llowing 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 wi...

Страница 104: ...ing 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 read...

Страница 105: ...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 Diagno...

Страница 106: ...ndicator 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 L...

Страница 107: ...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...

Страница 108: ...3 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...

Страница 109: ...o 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 d...

Страница 110: ...uit 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...

Страница 111: ...Automotive Horn 1 0 Contactor 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...

Страница 112: ...he GCON 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 4 For short to B typ...

Страница 113: ...latform 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 E...

Страница 114: ...f 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 COILFAUL...

Страница 115: ...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 ma...

Страница 116: ...N 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 f...

Страница 117: ...ft 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 a...

Страница 118: ...CM 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 EC...

Страница 119: ...Enable 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 Sh...

Страница 120: ...ll 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 circu...

Страница 121: ...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 ope...

Страница 122: ...safety 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...

Страница 123: ...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 c...

Страница 124: ...R61 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 contro...

Страница 125: ...rstand 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 Abo...

Страница 126: ...amp 48V DC battery charger F28 5 amp 24V DC battery balancer F29 5 amp 48V DC battery balancer FB Flashing beacon FB1 Option H Horn or alarm H2 Horn H5 Multi function alarm ground H8 Alarm platform JC...

Страница 127: ...controls terminal strip TS Toggle switch TS10 Auxiliary down ground TS51 Auxiliary down enable ground U Electronic Component U1 GCON ground U2 PCON platform U3A Right DCON U3B Left DCON U4 Battery ch...

Страница 128: ...3369 DC GS 4069 DC 117 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 Orang...

Страница 129: ...gger 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 Accumulato...

Страница 130: ...th 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 so...

Страница 131: ...e 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 wa...

Страница 132: ...ch 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 platform overload pressure switch S2...

Страница 133: ...Service and Repair Manual November 2016 122 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1272220GT This page intentionally left blank...

Страница 134: ...November 2016 Service and Repair Manual 123 Fuse Ground and Platform Control Boxes Fuse Box Layout All Models...

Страница 135: ...Service and Repair Manual November 2016 124 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1272220GT Fuse Box Layout All Models Fuse Box Layout All Models...

Страница 136: ...November 2016 Service and Repair Manual Part No 1272220GT GS 2669 DC GS 3369 DC GS 4069 DC 125 Ground C ontrol Box Layout All M odels Ground Control Box Layout All Models...

Страница 137: ...Service and Repair Manual November 2016 126 Ground Control Box Layout All Models...

Страница 138: ...November 2016 Service and Repair Manual 127 Platform Control Box Layout Models with 2 Speed Lift...

Страница 139: ...ervice and Repair Manual November 2016 128 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1272220GT Platform C ontrol Box Layout Models with 2 Speed Lift Platform Control Box Layout Models with 2 Speed Lift...

Страница 140: ...vember 2016 Service and Repair Manual Part No 1272220GT GS 2669 DC GS 3369 DC GS 4069 DC 129 Control Box Layout Models with Pr oporti onal Lift Platform Control Box Layout Models with Proportional Lif...

Страница 141: ...Service and Repair Manual November 2016 130 Platform Control Box Layout Models with Proportional Lift...

Страница 142: ...November 2016 Service and Repair Manual 131 Electrical Schematics AN SI C SA Electrical Schematic GS 2669 DC and GS 3369 DC with 2 Speed Lift ANSI CSA to serial number GS6915 6388...

Страница 143: ...DC GS 3369 DC GS 4069 DC Part No 1272220GT Electrical Schem atic GS 2669 DC and GS 3369 DC with 2 Speed Lift ANSI C SA to seri al num ber GS6915 6388 Electrical Schematic GS 2669 DC and GS 3369 DC wit...

Страница 144: ...69 DC GS 4069 DC 133 Electrical Schem atic GS 2669 DC and GS 3369 DC with Proporti onal Lift AN SI C SA from serial number GS6915 6389 to GS6915 7719 Electrical Schematic GS 2669 DC and GS 3369 DC wit...

Страница 145: ...Service and Repair Manual November 2016 134 Electrical Schematic GS 2669 DC and GS 3369 DC with Proportional Lift ANSI CSA from serial number GS6915 6389 to GS6915 7719...

Страница 146: ...November 2016 Service and Repair Manual 135 Electrical Schematic GS 2669 DC and GS 3369 DC with Proportional Lift ANSI CSA from serial number GS6915 7720...

Страница 147: ...369 DC GS 4069 DC Part No 1272220GT Electrical Schem atic GS 2669 DC and GS 3369 DC with Proporti onal Lift AN SI C SA from serial number GS6915 7720 Electrical Schematic GS 2669 DC and GS 3369 DC wit...

Страница 148: ...al Part No 1272220GT GS 2669 DC GS 3369 DC GS 4069 DC 137 Electrical Schem atic GS 4069 DC with 2 Speed Lift AN SI C SA to serial number GS6915 6388 Electrical Schematic GS 4069 DC with 2 Speed Lift A...

Страница 149: ...Service and Repair Manual November 2016 138 Electrical Schematic GS 4069 DC with 2 Speed Lift ANSI CSA to serial number GS6915 6388...

Страница 150: ...November 2016 Service and Repair Manual 139 Electrical Schematic GS 4069 DC with Proportional Lift ANSI CSA from serial number GS6915 6389 to GS6915 7719...

Страница 151: ...l Schem atic GS 4069 DC with Pr oporti onal Lift AN SI C SA fr om serial num ber GS6915 7720 Electrical Schematic GS 4069 DC with Proportional Lift ANSI CSA from serial number GS6915 7720 Electrical S...

Страница 152: ...vember 2016 Service and Repair Manual Part No 1272220GT GS 2669 DC GS 3369 DC GS 4069 DC 141 Electrical Schematic GS 4069 DC with Proportional Lift ANSI CSA from serial number GS6915 6386 to GS9615 77...

Страница 153: ...Service and Repair Manual November 2016 142 Electrical Schematic GS 2669 DC and GS 3369 DC with Proportional Lift ANSI CSA from serial number GS6915 7720...

Страница 154: ...November 2016 Service and Repair Manual 143 Electrical Schematics AS CE Electrical Schematic GS 2669 DC and GS 3369 DC with 2 Speed Lift AS CE to serial number GS6915 6388...

Страница 155: ...69 DC GS 3369 DC GS 4069 DC Part No 1272220GT Electrical Schem atic GS 2669 DC and GS 3369 DC with 2 Speed Lift AS C E to serial num ber GS6915 6388 Electrical Schematic GS 2669 DC and GS 3369 DC with...

Страница 156: ...S 3369 DC GS 4069 DC 145 Electrical Schem atic GS 2669 DC and GS 3369 DC with Proporti onal Lift AS CE from serial number GS6915 6389 to GS6915 7719 Electrical Schematic GS 2669 DC and GS 3369 DC with...

Страница 157: ...Service and Repair Manual November 2016 146 Electrical Schematic GS 2669 DC and GS 3369 DC with Proportional Lift AS CE from serial number GS6915 6389 to GS6915 7719...

Страница 158: ...November 2016 Service and Repair Manual 147 Electrical Schematic GS 2669 DC and GS 3369 DC with Proportional Lift AS CE from serial number GS6915 7720...

Страница 159: ...GS 3369 DC GS 4069 DC Part No 1272220GT Electrical Schem atic GS 2669 DC and GS 3369 DC with Proporti onal Lift AS CE from serial number GS6915 7720 Electrical Schematic GS 2669 DC and GS 3369 DC with...

Страница 160: ...anual Part No 1272220GT GS 2669 DC GS 3369 DC GS 4069 DC 149 Electrical Schem atic GS 4069 DC with 2 Speed Lift AS CE to seri al num ber GS6915 6388 Electrical Schematic GS 4069 DC with 2 Speed Lift A...

Страница 161: ...Service and Repair Manual November 2016 150 Electrical Schematic GS 4069 DC with 2 Speed Lift AS CE to serial number GS6915 6388...

Страница 162: ...November 2016 Service and Repair Manual 151 Electrical Schematic GS 4069 DC with Proportional Lift AS CE from serial number GS6915 6389 to GS6915 7719...

Страница 163: ...S 3369 DC GS 4069 DC Part No 1272220GT Electrical Schem atic GS 4069 DC with Pr oporti onal Lift AS CE fr om serial number GS6915 6389 to GS6915 7719 Electrical Schematic GS 4069 DC with Proportional...

Страница 164: ...art No 1272220GT GS 2669 DC GS 3369 DC GS 4069 DC 153 Electrical Schem atic GS 4069 DC with Pr oporti onal Lift AS CE fr om serial number GS6915 7720 Electrical Schematic GS 4069 DC with Proportional...

Страница 165: ...Service and Repair Manual November 2016 154 Electrical Schematic GS 4069 DC with Proportional Lift AS CE from serial number GS6915 7720...

Страница 166: ...November 2016 Service and Repair Manual 155 H ydraulic Schematics Hydraulic Schematic GS 2669 DC and GS 3369 DC with 2 Speed Lift to serial number GS6915 6388...

Страница 167: ...6 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1272220GT Hydraulic Schem atic GS 2669 DC and GS 3369 D C with 2 Speed Lift to serial num ber GS6915 6388 Hydraulic Schematic GS 2669 DC and GS 3369 DC with...

Страница 168: ...272220GT GS 2669 DC GS 3369 DC GS 4069 DC 157 Hydraulic Schem atic GS 2669 DC and GS 3369 D C with Proporti onal Lift from serial number GS6915 6389 Hydraulic Schematic GS 2669 DC and GS 3369 DC with...

Страница 169: ...Service and Repair Manual November 2016 158 Hydraulic Schematic GS 2669 DC and GS 3369 with Proportional Lift from serial number GS6915 6389...

Страница 170: ...November 2016 Service and Repair Manual 159 Hydraulic Schematic GS 4069 DC with 2 Speed Lift to serial number GS6915 6388...

Страница 171: ...ovember 2016 160 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1272220GT Hydraulic Schem atic GS 4069 DC with 2 Speed Lift to seri al num ber GS6915 6388 Hydraulic Schematic GS 4069 DC with 2 Speed Lift to...

Страница 172: ...anual Part No 1272220GT GS 2669 DC GS 3369 DC GS 4069 DC 161 Hydraulic Schem atic GS 4069 DC with Pr oporti onal Lift fr om serial number GS6915 6389 Hydraulic Schematic GS 4069 DC with Proportional L...

Страница 173: ...Service and Repair Manual November 2016 162 Hydraulic Schematic GS 4069 DC with Proportional Lift from serial number GS6915 6389...

Страница 174: ...November 2016 Service and Repair Manual 163 Hydraulic Schematic GS 2669 DC and GS 3369 DC with Proportional Relief from serial number GS6916F 10015...

Страница 175: ...2669 DC GS 3369 DC GS 4069 DC Part No 1272220GT Hydraulic Schem atic GS 2669 DC and GS 3369 D C with 2 Speed Lift to serial num ber GS6915 6388 Hydraulic Schematic GS 2669 DC and GS 3369 DC with Propo...

Страница 176: ...rt No 1272220GT GS 2669 DC GS 3369 DC GS 4069 DC 165 Hydraulic Schem atic GS 2669 DC and GS 3369 D C with Proporti onal Lift from serial number GS6915 6389 Hydraulic Schematic GS 4069 DC with Proporti...

Страница 177: ...r Manual November 2016 166 Hydraulic Schematic GS 2669 DC and GS 3369 with Proportional Lift from serial number GS6915 6389 GS 2669 DC GS 3369 DC GS 4069 DC Part No 1272220GT Service and R epair M anu...

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