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Terex Genie GS-2669 DC User Manual

Terex Genie GS-2669 DC
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Service and Repair Manual
GS
-2669 DC
from GS69F-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

Table of Contents

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Terex Genie GS-2669 DC Specifications

General IconGeneral
Drive TypeElectric
Gradeability35%
Drive Speed - Lowered2.5 mph
Drive Speed - Raised0.5 mph
Power Source48 V DC
Max Travel Speed2.5 mph
Battery8 x 6 V 350 Ah

Summary

Introduction

Important Information

Key safety and operating instructions for using the manual.

Compliance

Machine classification and design life information.

Technical Publications

Information on accuracy and product updates.

Revision History

Serial Number Legend

Safety Rules

General Safety Rules

Essential safety precautions before performing maintenance.

Personal Safety

Guidelines for individual safety while working with machinery.

Workplace Safety

Recommendations for maintaining a safe work environment.

Specifications

Machine Specifications

Details on fluid capacities, tires, and wheels.

Performance Specifications

Information on drive speed, braking, and function speeds.

Hydraulic Oil Specifications

Requirements and recommendations for hydraulic fluids.

Hydraulic Component Specifications

Specifications for the function pump and manifold.

Manifold Component Specifications

Torque specifications for manifold components.

Machine Component Weights

Weight details for various machine assemblies.

Battery Specifications

Specifications for T105 and J305GH battery types.

Hydraulic Hose and Fitting Torque Specifications

Torque values for Seal-Lok, JIC, and O-ring boss port fittings.

Torque Procedure

Steps for properly torquing Seal-Lok and JIC fittings.

Repair Procedures

Introduction

Guidelines for performing repair procedures safely and effectively.

About This Section

Guidance on selecting and performing repair procedures.

Symbols Legend

Explanation of symbols used in repair procedures.

Platform Controls

Operational Indicator Codes (OIC)

Codes indicating machine status, not malfunctions.

How to Remove the Platform Controls Circuit Board

Step-by-step instructions for removing the circuit board.

How to Remove the Joystick

Detailed steps for removing the joystick assembly.

How to Remove the Platform Controls Alarm

Procedure for removing the platform alarm component.

How to Remove the Platform Emergency Stop Button

Steps to remove the emergency stop button from the platform.

Platform Components

How to Remove the Platform

Instructions for safely removing the machine's platform.

How to Remove the Platform Extension Deck

Steps for detaching the platform extension deck.

Scissor Components

How to Disassemble the Scissor Assembly, GS-2669 DC

Procedure for disassembling the GS-2669 scissor assembly.

How to Disassemble the Scissor Assembly, GS-3369 DC

Procedure for disassembling the GS-3369 scissor assembly.

How to Disassemble the Scissor Assembly, GS-4069 DC

Procedure for disassembling the GS-4069 scissor assembly.

How to Replace the Scissor Arm Wear Pad

Steps for replacing scissor arm slider blocks and wear pads.

How to Remove the Lift Cylinder

Procedures for removing lift cylinders for GS-2669, GS-3369, and GS-4069.

How to Replace the Height Angle Sensor

Instructions for replacing the height angle sensor and magnet.

Ground Controls

How to Determine the Software Revision Level

Steps to find the machine's software revision level.

How to Setup the Machine from Ground Controls

Procedure for setting machine parameters via ground controls.

Auxiliary Platform Lowering

Procedure for lowering platform during power failure.

How to Install and Calibrate the Level Sensor

Steps for installing and calibrating the level sensor.

How to Install the Outrigger Level Sensor

Instructions for installing the outrigger level sensor.

Service Override Mode

Procedure for enabling service override mode.

Hydraulic Pump

How to Test the Hydraulic Pump

Procedure for testing the hydraulic pump's performance.

How to Remove the Hydraulic Pump

Steps to safely remove the hydraulic pump.

How to Calibrate the Hydraulic Pump

Procedure for calibrating the hydraulic pump.

Manifolds

Function Manifold Components

Identification and torque specs for function manifold parts.

How to Check the System Proportional Relief Valve

Procedure to check the system proportional relief valve.

How to Adjust the Oscillate Relief Valve

Steps to adjust the oscillate relief valve pressure.

How to Adjust the Steer Relief Valve

Procedure to adjust the steer relief valve pressure.

How to Adjust the Platform Up Relief Valve

Instructions for adjusting the platform up relief valve.

Outrigger Manifold Components

Details of the outrigger manifold components.

How to Test a Coil

Procedure for testing solenoid valve coils.

How to Test a Coil Diode

Procedure for testing coil diodes for circuit protection.

Hydraulic Tank

How to Remove the Hydraulic Tank

Steps for safely removing the hydraulic tank.

Steer Axle Components

How to Remove the Yoke Assembly

Detailed instructions for removing the yoke assembly.

How to Remove a Drive Motor

Procedure for removing the drive motor.

How to Remove the Steer Cylinder

Steps to remove the steer cylinder.

How to Remove the Tie Rod

Procedure for removing the tie rod.

How to Remove the Oscillate Cylinder

Instructions for removing the oscillate cylinder.

Test the Oscillate Axle Hose Routing

Procedure to test oscillate axle hose routing.

How to Replace the Steer Angle Sensor

Steps for replacing the steer angle sensor.

How to Calibrate the Steer Angle Sensor

Procedure for calibrating the steer angle sensor.

Non-steer Axle Components

How to Remove a Drive Motor

Steps for removing the drive motor.

How to Remove a Drive Hub

Procedure for removing the drive hub.

Outrigger Components

How to Remove an Outrigger Cylinder (if equipped)

Steps for removing the outrigger cylinder.

How to Calibrate the Outrigger System

Procedure for calibrating the outrigger system.

Platform Overload Components

How to Calibrate the Platform Overload System

Steps to calibrate the platform overload system.

How to Clear the Platform Overload Recovery Message

Procedure to clear the platform overload recovery message.

How to Calibrate the Down Limit Height

Procedure to calibrate the platform down limit height.

Fault Codes

Introduction

Overview of using fault codes for troubleshooting.

About This Section

How fault codes aid in pinpointing malfunctions.

Definitions

Glossary of diagnostic system and code acronyms.

Genie SmartLink Diagnostic System

Overview of the diagnostic system.

GCON I/O Map

Pinout and circuit functions for ground controls.

Control System Fault Codes

Explanation of numerical fault codes displayed on LED.

Platform Overload Fault Codes

Fault codes related to platform overload system.

Operation Indicator Codes (OIC)

Codes indicating machine operational status.

Diagnostic Trouble Codes (DTC)

Categories of codes indicating electrical system malfunctions.

Troubleshooting "HXXX" and "PXXX" Faults

Steps for diagnosing HXXX and PXXX fault types.

Fault Inspection Procedure

Procedure for inspecting devices and harnesses related to faults.

Type "HXXX" Faults

List of HXXX fault codes, descriptions, causes, and failure modes.

Type "PXXX" Faults

List of PXXX fault codes, descriptions, causes, and failure modes.

Type "UXXX" Faults

List of UXXX fault codes, descriptions, causes, and failure modes.

Type "FXXX" Faults

List of FXXX fault codes, descriptions, causes, and failure modes.

Type "CXXX" Faults

List of CXXX fault codes, descriptions, causes, and failure modes.

Schematics

Introduction

Overview of schematics section.

About This Section

Information about the schematic groups.

Electrical Schematics

Safety warnings for electrical schematics.

Hydraulic Schematics

Safety warnings for hydraulic schematics.

Electrical Schematic Abbreviations and Wire Color Legends

Legend for electrical symbols and wire colors.

Hydraulic Component Legend

Legend for hydraulic symbols and components.

Electrical Symbols Legend

Visual representation of common electrical symbols.

Hydraulic Symbols Legend

Visual representation of common hydraulic symbols.

Limit Switch Legend

Identification of limit switch locations and designations.

Fuse Box Layout, All Models

Diagram showing fuse box component layout.

Ground Control Box Layout

Diagram showing ground control box components.

Platform Control Box Layout

Diagram showing platform control box components.

Electrical Schematic

Full electrical schematic diagram of the machine.

Hydraulic Schematic

Full hydraulic schematic diagram of the machine.

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