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Genie GS-2669 RT Service Manual

Genie GS-2669 RT
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Parts Manual
Serial Number Range
Service Manual
Part No. 229753
Rev D2
November 2014
Serial Number Range
GS-2669 RT
from GS6911-101
GS-3369 RT
GS-4069 RT

Table of Contents

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Genie GS-2669 RT Specifications

General IconGeneral
BrandGenie
ModelGS-2669 RT
CategoryBoom Lifts
LanguageEnglish

Summary

Service Manual

Serial Number Range

Identifies the serial number range for the models covered.

Introduction

Important Information

Key safety and operational instructions for maintenance.

Compliance

Details machine classification and design life as per standards.

Technical Publications

Notes on accuracy, product improvement, and change policy.

Contact Information

Information on how to contact Genie for support and inquiries.

Revision History

Serial Number Legend

Safety Rules

Personal Safety

Guidelines for individual safety when operating or maintaining the machine.

Safety Rules

Workplace Safety

Guidelines for maintaining a safe and hazard-free work area.

Repair Procedures

Platform Components

Procedures for removing and servicing platform-related parts.

Scissor Components

Procedures for disassembling and servicing the scissor lift mechanism.

Specifications

Machine Specifications

Provides detailed specifications for fluid capacities, tires, and weight.

Performance Specifications

Details drive speed, braking distance, gradeability, and function speeds.

Hydraulic Specifications

Specifications for hydraulic oil type, cleanliness, and optional fluids.

Kubota D1105 Engine Specifications

Technical specifications for the Kubota D1105 engine.

Hydraulic Hose and Fitting Torque Specifications

Torque values for Seal-Lok™ and JIC 37° fittings and SAE O-ring boss ports.

Scheduled Maintenance Procedures

Observe and Obey During Maintenance

Key instructions and safety precautions before performing maintenance.

Symbols Legend

Explains symbols used to convey procedural information and warnings.

Scheduled Maintenance Procedures (continued)

Maintenance Schedule

Details the types and frequencies of maintenance inspections required.

Maintenance Inspection Report

Information on the maintenance inspection report and record-keeping requirements.

Pre-Delivery Preparation

Pre-Delivery Preparation Instructions

Steps and legend for completing the pre-delivery inspection form.

Checklist A Procedures

Inspect Manuals and Decals

Procedure to check operator and safety manuals and decals for legibility and completeness.

Checklist A Procedures (continued)

Perform Pre-operation Inspection

Visual inspection performed by the operator before each work shift.

Perform Function Tests

Tests to ensure all machine functions are operating correctly.

Checklist A Procedures (continued)

Perform Engine Maintenance

Routine engine checks and maintenance procedures.

Test the Oscillate Axle

Procedure to verify the proper function of the oscillate system for stability.

Checklist A Procedures (continued)

Inspect Engine Air Filter

Procedure to inspect and clean the engine air filter element for performance.

Checklist A Procedures (continued)

Perform 30 Day Service

One-time service sequence performed after the first 30 days or 40 hours of usage.

Perform Engine Maintenance - Kubota Models (50 Hour Service)

Engine maintenance including oil and filter change at 50 hours.

Checklist A Procedures (continued)

Replace Drive Hub Oil

Procedure for replacing the oil in the drive hubs after 150 hours.

Perform Engine Maintenance - Kubota Models (200 Hour Service)

Engine maintenance including oil/filter change, hose inspection, and air intake hose check.

Checklist A Procedures (continued)

Drain Fuel Filter/Water Separator - Kubota Diesel Models

Procedure to drain water and sediment from the fuel filter/water separator.

Checklist A Procedures (continued)

Perform Engine Maintenance - Kubota Diesel Models (Monthly/2 Months)

Procedure to recharge the battery for Kubota diesel engines.

Checklist B Procedures

Inspect the Battery

Procedure to inspect battery condition, fluid levels, and specific gravity.

Checklist B Procedures (continued)

Inspect Electrical Wiring

Procedure to inspect wiring for damage, corrosion, or loose connections.

Checklist B Procedures (continued)

Inspect Tires, Wheels, and Lug Bolt Torque

Procedure to check tire condition, wheel damage, and lug bolt torque.

Checklist B Procedures (continued)

Test the Key Switch

Procedure to verify the proper operation of the key switch for control selection.

Checklist B Procedures (continued)

Test the Emergency Stop Button

Procedure to test the function of the emergency stop buttons on both controls.

Checklist B Procedures (continued)

Test the Drive Brakes

Procedure to test the drive brake function for smooth, responsive operation.

Checklist B Procedures (continued)

Test Drive Speed - Stowed Position

Procedure to measure drive speed in the stowed position for performance verification.

Checklist B Procedures (continued)

Test Drive Speed - Raised Position

Procedure to measure drive speed in the raised position for performance verification.

Checklist B Procedures (continued)

Perform Hydraulic Oil Analysis

Procedure to test hydraulic oil for contamination levels for machine performance.

Checklist B Procedures (continued)

Check Drive Hub Oil Level

Procedure to check and maintain the oil level in the drive hubs for proper operation.

Checklist C Procedures

Test Platform Overload System (if equipped)

Procedure to calibrate the platform overload system for safe operation.

Checklist C Procedures (continued)

Check Descent Delay Function (if equipped)

Procedure to check the descent delay function of the down limit switch.

Checklist C Procedures (continued)

Clean Fuel Tank - Diesel Models

Procedure to remove sediment from the fuel tank for engine performance.

Checklist C Procedures (continued)

Replace Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil

Procedure to replace the hydraulic tank breather cap to prevent contamination.

Checklist C Procedures (continued)

Perform Engine Maintenance - Diesel Models (500 Hour Service)

Maintenance for Kubota D1105 and Perkins 403D-11 diesel engines.

Perform Engine Maintenance - Kubota Diesel Models (800 Hour Service)

Engine maintenance including inspecting valve clearance for Kubota diesel.

Checklist D Procedures

Check Scissor Arm Wear Pads and Slider Blocks

Procedure to measure wear pads and slider blocks for wear.

Replace Hydraulic Tank Return Filter

Procedure to replace the hydraulic tank return filter for system performance.

Checklist D Procedures (continued)

Perform Engine Maintenance - Kubota Models (Annual Service)

Annual engine maintenance for Kubota models including air filter and carburetor.

Checklist D Procedures (continued)

Perform Engine Maintenance - Perkins Models (1000 Hour Service)

Engine maintenance for Perkins models including fan belt and valve lash.

Perform Engine Maintenance - Kubota Gas/LPG Models (1000 Hour Service)

Engine maintenance for Kubota Gas/LPG models including spark plugs and coolant system.

Checklist D Procedures (continued)

Replace Drive Hub Oil

Procedure for replacing the oil in the drive hubs at 1000 hours or annually.

Perform Engine Maintenance - Kubota Diesel Models (1500 Hour Service)

Maintenance for Kubota diesel models including inspecting injectors.

Checklist E Procedures

Test or Replace Hydraulic Oil

Procedure to test or replace hydraulic oil at 2000 hours or two years.

Checklist E Procedures (continued)

Perform Engine Maintenance - Perkins Models (2000 Hour Service)

Maintenance for Perkins models including alternator, breather, engine mounts, and starter.

Checklist E Procedures (continued)

Perform Engine Maintenance - Kubota Gas/LPG Models (Two Year Service)

Two-year maintenance for Kubota Gas/LPG models including hoses and filters.

Perform Engine Maintenance - Kubota Diesel Models (Two Year Service)

Two-year maintenance for Kubota diesel models including hoses, coolant, and air intake.

Checklist E Procedures (continued)

Perform Engine Maintenance - Perkins Models (3000 Hour Service)

Maintenance for Perkins models including fuel injectors, water pump, and coolant system.

Perform Engine Maintenance - Kubota Diesel Models (3000 Hour Service)

Maintenance for Kubota diesel models including injection pump and timing.

Repair Procedures

Observe and Obey During Repairs

Critical safety and procedural notes for performing repair procedures.

Before Repairs Start

Essential preparation steps and safety checks before commencing repairs.

Platform Controls

Circuit Boards

Procedure for removing the platform controls circuit board.

Platform Components

Platform Removal

Step-by-step procedure for removing the platform from the machine.

Scissor Components

Scissor Assembly, GS-2669 RT - Disassembly

Step-by-step procedure to disassemble the scissor assembly for the GS-2669 RT.

Scissor Assembly, GS-3369 RT - Disassembly

Step-by-step procedure to disassemble the scissor assembly for the GS-3369 RT.

Scissor Assembly, GS-4069 RT - Disassembly

Step-by-step procedure to disassemble the scissor assembly for the GS-4069 RT.

Wear Pads Replacement

Procedure for replacing scissor arm wear pads and slider blocks.

Scissor Components (continued)

Lift Cylinder(s)

Information and removal procedures for lift cylinders.

Kubota D1105 Engine

Timing Adjustment

Information on timing adjustment, noting it is factory sealed.

Check Glow Plugs

Procedure to test glow plug resistance and voltage.

Kubota D1105 Engine (continued)

Adjust Engine RPM

Procedure to adjust low and high idle engine RPM for Kubota D1105.

Flex Plate Removal and Installation

Procedures for removing and installing the flex plate.

Kubota D1105 Engine (continued)

Coolant Temperature and Oil Pressure Switches

Explanation of switch operation and procedure for replacement.

Kubota WG972 Engine

Timing Adjustment

Information on timing adjustment, noting it's factory sealed.

Carburetor Adjustment

Information on carburetor adjustment, noting it's factory sealed.

Choke Adjustment

Details choke operation and mode limitations.

Perkins 403D-11 Engine

Adjust Engine RPM

Procedure to adjust low and high idle engine RPM for Perkins engines.

Ground Controls

Function Speed Tuning

Procedures to adjust function speeds to compensate for wear.

Determine Revision Level

Procedure to check the ECM software revision level.

Ground Controls (continued)

Adjust Stowed Drive Speed

Procedure to adjust the stowed drive speed for optimal performance.

Ground Controls (continued)

Adjust Stowed High Torque Drive Speed

Procedure to adjust the stowed high torque drive speed.

Ground Controls (continued)

Adjust Raised Drive Speed

Procedure to adjust the raised drive speed for optimal performance.

Ground Controls (continued)

Adjust Lift Speed

Procedure to adjust the lift speed for optimal platform movement.

Ground Controls (continued)

Software Configuration

Procedures for configuring machine settings via the ground controls.

Machine Option Definitions

Explains various machine options like Descent Delay, Motion Alarm, and Overload.

Ground Controls (continued)

Level Sensor - Models without Outriggers

Information and calibration procedures for the level sensor on non-outrigger models.

Ground Controls (continued)

Level Sensor - Models with Outriggers

Information and calibration procedures for the level sensor on outrigger models.

Hydraulic Pump

Test Hydraulic Pump

Procedure to test the hydraulic pump pressure output.

Remove Hydraulic Pump

Procedure for removing the hydraulic pump assembly.

Hydraulic Pump (continued)

Prime the Hydraulic Pump

Procedure for priming the hydraulic pump after replacement or service.

Manifolds

Function Manifold Components

Lists and describes components of the function manifold with torque values.

Manifolds (continued)

Valve Adjustments - Function Manifold

Procedure to adjust the system relief valve pressure on the function manifold.

Manifolds (continued)

Adjust Oscillate Relief Valve

Procedure to adjust the oscillate relief valve pressure.

Manifolds (continued)

Adjust Platform Up Relief Valve (with Platform Overload)

Procedure to adjust platform up relief valve pressure for models with overload system.

Manifolds (continued)

Outrigger Manifold Components

Identifies components of the outrigger manifold.

Manifolds (continued)

Traction Manifold Components - View 1

Lists components of the traction manifold (View 1) with functions and torque.

Manifolds (continued)

Generator Manifold Components

Identifies components of the generator manifold with functions and torque.

Manifolds (continued)

Valve Coils - Resistance Specification

Specifications for testing valve coil resistance at different temperatures.

Manifolds (continued)

Test Coils Using Test System Function

Procedure to test coils using the ECM's built-in test system.

Fuel and Hydraulic Tanks

Fuel Tank Removal

Procedure for removing the fuel tank.

Fuel and Hydraulic Tanks (continued)

Hydraulic Tank Removal

Procedure for removing the hydraulic tank.

Steer Axle Components

Yoke and Drive Motor Removal

Procedures for removing the yoke and drive motor assembly.

Steer Axle Components (continued)

Remove Drive Motor

Procedure for removing the drive motor from the yoke.

Steer Cylinder Removal

Procedure for removing the steer cylinder.

Steer Axle Components (continued)

Tie Rod Removal

Procedure for removing the tie rod.

Oscillate Cylinder Removal

Procedure for removing the oscillate cylinder.

Steer Axle Components (continued)

Oscillate Axle Hose Routing Test

Procedure to test the routing of oscillate axle hoses.

Non-steer Axle Components

Drive Motor / Brake Assembly Removal

Procedures for removing the drive motor/brake assembly.

Non-steer Axle Components (continued)

Drive Hub Removal

Procedure for removing the drive hub.

Outrigger Components

Outrigger Cylinder Removal (if equipped)

Procedure for removing the outrigger cylinder, if equipped.

Platform Overload Components

Calibrate Platform Overload System (if equipped)

Procedure to calibrate the platform overload system for safe operation.

Platform Overload Components (continued)

Check Maximum Height Limit Switch

Procedure to test the maximum height limit switch for proper operation.

Fault Codes

Before Troubleshooting

Safety and preparation guidelines before starting troubleshooting.

Observe and Obey During Troubleshooting

Critical safety and procedural notes for troubleshooting and repair.

Fault Codes (continued)

General Repair Process for Troubleshooting

Diagram illustrating the general process for diagnosing and repairing malfunctions using fault codes.

Ground Control LED Diagnostic Readout

Explanation of the diagnostic readout display and fault codes.

Fault Code Chart

Error Source Codes

Lists error IDs and names related to ECU and switch faults.

Fault Conditions

Describes the conditions under which specific faults occur.

Fault Solutions

Provides solutions or troubleshooting steps for identified faults.

Schematics

About This Section

Overview of the schematics section, categorizing into electrical and hydraulic.

Electrical Schematics

Details the electrical system of the machine.

Hydraulic Schematics

Details the hydraulic system of the machine.

Schematics (continued)

Electronic Control Module (ECM) Pin-Out Legend

Details the pin assignments for the Electronic Control Module connectors.

Schematics (continued)

Electrical, Wire Color, and Hydraulic Legends

Defines abbreviations, wire colors, and hydraulic component symbols.

Schematics (continued)

Electrical Symbols Legend

Defines common electrical symbols used in schematics.

Schematics (continued)

Hydraulic Symbols Legend

Defines common hydraulic symbols used in schematics.

Schematics (continued)

Limit Switch Legend

Identifies and defines the location and function of various limit switches.

Schematics (continued)

Control Panel Circuit Diagram

Illustrates the circuit diagram for the control panels.

Electrical Schematic - GS-2669/3369 RT, Gas/LPG (ANSI/CSA)

Electrical Schematic - GS-2669/3369 RT, Diesel (ANSI/CSA)

Electrical Schematic - GS-2669/3369 RT, Gas/LPG (AS)

Electrical Schematic - GS-2669/3369 RT, Diesel (AS)

Electrical Schematic - GS-2669/3369 RT, Gas/LPG (CE)

Electrical Schematic - GS-2669/3369 RT, Diesel (CE)

Electrical Schematic - GS-4069 RT, Gas/LPG (ANSI / CSA)

Electrical Schematic - GS-4069 RT, Diesel Models (ANSI / CSA)

Electrical Schematic - GS-4069 RT, Gas / LPG Models (AS)

Electrical Schematic - GS-4069 RT, Diesel Models (AS)

Electrical Schematic - GS-4069 RT, Gas / LPG Models (CE)

Electrical Schematic - GS-4069 RT, Diesel Models (CE)

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