Terex Genie GS-3369 BE - User Manual

Service Manual
GS-2669 BE
GS-3369 BE
GS-4069 BE
Part No. 1257106
Rev A3
May 2015

Summary

Introduction

Important Information

Safety and operational instructions are crucial for maintenance. Operator's manual is key.

Compliance

Machine classification and design life details.

Technical Publications

Information regarding accuracy, continuous improvement, and feedback.

Contact Us:

Contact information for Genie.

Find a Manual for this Model

Instructions on locating manuals online.

Revision History

Reference Examples:

Examples of how to reference sections for updates and procedures.

Serial Number Legend

Safety Rules

Danger

Warning about severe injury or death from not following safety rules.

Do Not Perform Maintenance Unless:

Conditions required before performing maintenance.

Personal Safety

Awareness of hazards and safe operation when working on or around machines.

Workplace Safety

Awareness of hazards and safe operation in the work area.

Specifications

Machine Specifications

Details fluid capacities, tire specifications, and torque values for machine components.

Performance Specifications

Maximum drive speeds, braking distance, gradeability, and function speeds.

Hydraulic Specifications

Requirements for hydraulic oils, cleanliness, and recommended fluids.

Chevron Rando HD Premium Oil MV Fluid Properties

Properties of Chevron Rando HD Premium Oil MV.

Chevron 5606 A Hydraulic Oil Fluid Properties

Fluid properties of Chevron 5606A Hydraulic Oil.

Petro-Canada Environ MV 46 Fluid Properties

Fluid properties of Petro-Canada Environ MV 46.

UCON Hydrolube HP-5046 Fluid Properties

Fluid properties of UCON Hydrolube HP-5046.

Hydraulic Component Specifications

Specifications for drive pump and function manifold components.

Manifold Component Specifications

Torque specifications for manifold components.

Battery Specifications

Specifications for T105 and T145 battery types.

Kohler KD350 Engine

Engine specifications including displacement, bore, stroke, horsepower, and oil requirements.

Hydraulic Hose and Fitting Torque Specifications

Torque specifications for Seal-Lok and JIC fittings.

Torque Procedure

Procedures for applying torque to Seal-Lok and JIC fittings.

SAE TORQUE CHART

Torque values for SAE fasteners.

METRIC FASTENER TORQUE CHART

Torque values for metric fasteners.

Scheduled Maintenance Procedures

Observe and Obey:

General rules for performing maintenance inspections safely and correctly.

Machine Configuration:

Specifies the required machine setup for performing maintenance procedures.

About This Section

Describes the content and purpose of the scheduled maintenance section.

Symbols Legend

Explains the meaning of symbols used in maintenance procedures.

Maintenance Symbols Legend

Explains symbols indicating tools, parts, dealer service, and engine status.

Pre-delivery Preparation Report

Details the pre-delivery preparation report and its purpose.

Maintenance Schedule

Outlines inspection frequency and required checklists based on operating hours.

Maintenance Inspection Report

Information on using and maintaining the maintenance inspection report.

Pre-Delivery Preparation Report

Fundamentals

States dealer responsibility for pre-delivery preparation and machine condition.

Instructions

Guides on using the operator's manual and recording inspection results.

Legend

Defines symbols for inspection results (Y, N, R).

Maintenance Inspection Report

Instructions

How to use the report, select checklists, and perform inspections.

Legend

Defines symbols for inspection results (Y, N, R).

Checklist A Procedures

Procedures for inspecting manuals, decals, pre-operation, and function tests.

Checklist B Procedures

Procedures for inspecting batteries, wiring, tires, brakes, and engine.

Checklist C Procedures

Procedures for testing platform overload, limit switches, and engine maintenance.

Checklist D Procedures

Procedures for checking wear pads and drive hub oil.

Checklist E Procedures

Procedures for hydraulic oil testing and wheel bearing greasing.

Checklist A Procedures

Inspect the Manuals and Decals

Verifies presence, legibility, and condition of manuals and decals.

Perform Pre-operation Inspection

Visual inspection before operation to identify issues and maintenance needs.

Perform Function Tests

Tests machine functions to ensure safe operation before use.

Perform Engine Maintenance

Routine engine maintenance including oil level and air filter checks.

Test the Oscillate Axle

Tests the oscillate system for proper axle contact and stability.

Perform 30-Day Service

A one-time procedure after initial usage, referring to other checklists.

Perform Engine Maintenance

Engine maintenance after initial usage, including oil and filter replacement.

Replace the Drive Hub Oil

Procedure for replacing drive hub oil after initial usage.

Checklist B Procedures

Inspect the Batteries

Inspects battery connections, tightness, and specific gravity for proper condition.

Inspect the Electrical Wiring

Inspects wiring for damage, chafing, corrosion, and ensures proper dielectric grease in connectors.

Inspect the Tires, Wheels and Castle Nut Torque

Checks tire condition, wheel damage, and torques castle and lug nuts.

Perform Engine Maintenance

Engine maintenance including oil and filter replacement.

Test the Emergency Stop

Tests the function and response of the Emergency Stop buttons.

Test the Key Switch

Tests the key switch operation for proper control panel activation.

Test the Automotive-style Horn (if equipped)

Tests the horn function for ground personnel warning.

Test the Drive Brakes

Tests drive brake action for smooth operation and holding capability.

Test the Drive Speed - Stowed Position

Measures drive speed in the stowed position.

Test the Drive Speed - Raised Position

Measures drive speed in the raised position.

Check the Electrical Contactor

Inspects contact points of the electrical contactor for burns, arcs, or pitting.

Perform Hydraulic Oil Analysis

Essential for performance and life; tests oil for contamination.

Inspect the Fuel and Hydraulic Tank Cap Venting Systems

Checks tank cap venting for proper air flow to ensure performance.

Check the Drive Hub Oil Level and Fastener Torque

Checks drive hub oil level and torque of mounting bolts.

Checklist C Procedures

Test the Platform Overload System (if equipped)

Tests the overload system's ability to sense overload and stop platform movement.

Down Limit Switch Descent Delay (if equipped)

Checks the delay function of the down limit switch.

Check the Down Limit Switch Rocker Arm Orientation (if equipped)

Verifies the orientation of the down limit switch rocker arms.

Check the Descent Delay Function

Verifies the descent delay function operates correctly.

Check the Down Limit Switch Height

Measures the distance related to the down limit switch activation.

Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil

Replaces the hydraulic tank breather cap to ensure proper venting.

Perform Engine Maintenance

Engine maintenance including fuel tank, oil, and filters.

Checklist D Procedures

Check Scissor Arm Wear Pads and Slider Blocks

Measures wear pad and slider block thickness for proper condition.

Replace the Drive Hub Oil

Procedure for replacing drive hub oil.

Test the Function Pump

Tests the function pump's efficiency by measuring platform raise time.

Checklist E Procedures

Test or Replace the Hydraulic Oil

Tests or replaces hydraulic oil for performance and service life.

Grease the Steer Axle Wheel Bearings

Greases steer axle wheel bearings for safe operation and service life.

Repair Procedures

Observe and Obey:

Rules for qualified personnel performing repair procedures safely.

Before Repairs Start:

Essential steps and precautions before starting repairs.

Machine Configuration:

Specifies the required machine setup for performing repair procedures.

About This Section

Describes the content of the repair procedures section.

Symbols Legend

Explains symbols used in repair procedures.

Platform Controls

Platform controls

Describes the purpose and components of platform controls.

Operational Indicator Codes

Explains system codes indicating operating status or malfunctions.

Circuit Board

Instructions for removing and installing the platform controls circuit board.

Joystick

Instructions for removing and installing the joystick.

Platform Controls Alarm

Instructions for removing and installing the platform controls alarm.

Platform Emergency Stop Button

Instructions for removing and installing the platform emergency stop button.

Platform Components

Platform

Procedures for removing and installing the platform, including safety warnings.

Platform Extension Deck

Instructions for removing and installing the platform extension deck.

Scissor Components

Scissor Assembly, GS-2669 BE

Procedure for disassembling the scissor assembly for the GS-2669 BE model.

Scissor Assembly, GS-3369 BE

Procedure for disassembling the scissor assembly for the GS-3369 BE model.

Scissor Assembly, GS-4069 BE

Procedure for disassembling the scissor assembly for the GS-4069 BE model.

Wear Pads

Procedures for replacing scissor arm wear pads and slider blocks.

Lift Cylinders

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

Manifolds

Function Manifold Components

Lists components of the function manifold with schematic items and torque values.

Valve Adjustments - Function Manifold

Procedures for adjusting system, oscillate, and steer relief valves.

How to Adjust the System Relief Valve

Step-by-step guide to adjust the system relief valve pressure.

How to Adjust the Oscillate Relief Valve

Step-by-step guide to adjust the oscillate relief valve pressure.

How to Adjust the Steer Relief Valve

Step-by-step guide to adjust the steer relief valve pressure.

How to Adjust the Platform Up Relief Valve - Models with Platform Overload

Adjusts platform up relief valve for models with overload system.

How to Adjust the Platform Up Relief Valve - Models without Platform Overload

Adjusts platform up relief valve for models without overload system.

Outrigger Manifold Components

Lists components of the outrigger manifold.

Valve Coils

Information on valve coils and testing.

How to Test a Coil

Procedure for testing valve coil resistance.

How to Test a Coil Diode

Procedure for testing the coil diode.

Fuel and Hydraulic Tanks

Fuel Tank

Procedures for removing the fuel tank, including safety precautions.

Hydraulic Tank

Procedures for removing the hydraulic tank, with safety and damage warnings.

Steer Axle Components

Yoke Assembly

Procedures for removing the yoke assembly, including safety precautions.

How to Remove a Drive Motor

Procedures for removing the drive motor, with warnings about work area cleanliness.

Steer Cylinder

Procedures for removing the steer cylinder, with safety warnings.

Tie Rod

Procedures for removing the tie rod, including safety precautions.

Oscillate Cylinder

Procedures for removing the oscillate cylinder, with safety warnings.

Oscillate Hoses

Procedure for testing oscillate axle hose routing.

Test the Oscillate Axle Hose Routing

Procedure to test hose routing after removal or replacement.

Check the Steering

Verifies correct steering action and axle oscillation.

Steer Angle Sensor

Procedures for replacing and calibrating the steer angle sensor.

How to Replace the Steer Angle Sensor

Step-by-step guide to replace the steer angle sensor.

How to Calibrate the Steer Angle Sensor

Procedure to calibrate the steer angle sensor using ground controls.

Non-steer Axle Components

Drive Motors

Procedures for removing drive motors, including safety and component damage warnings.

Drive Hub

Procedures for removing the drive hub, with warnings about unbalancing and dealer service.

Outrigger Components

Outrigger Cylinder

Procedures for removing the outrigger cylinder, including safety and re-calibration notes.

Outrigger Calibration

Procedure to calibrate the outrigger level sensor for machine leveling.

Platform Overload Components

Platform Overload System (if equipped)

Procedures for calibrating the platform overload system.

Check the Maximum Height Limit Switch

Tests the maximum height limit switch for proper activation.

Platform Overload System Troubleshooting

Table of conditions, possible causes, and solutions for platform overload system issues.

Platform Overload Recovery Message

Procedures to clear the overload recovery message from the LCD screen.

Battery Charger

Battery Charger

Information on the machine's battery chargers and setting selector curves.

Fault Codes

Observe and Obey:

Safety rules and procedures for troubleshooting and repair.

Before Troubleshooting:

Essential steps and precautions before starting troubleshooting.

About This Section

Explains how fault code charts help pinpoint problems and required tools.

General Repair Process

Outlines the basic steps for troubleshooting and repair.

Definitions

Defines acronyms and terms used in fault code sections.

Genie SmartLink Diagnostic System

Explains the GSDS for indicating malfunctions via OIC and DTC codes.

GCON ECM Connector Layout

Diagrams showing ECM connector layouts for models with and without outriggers.

GCON I;O MAP

Input/Output map for Ground Controls ECM, detailing circuits, function, and wire colors.

C3 Connector - Green

Lists circuits and I/O types for the C3 connector.

C4 Connector - Brown (Outrigger Option)

Lists circuits and I/O types for the C4 connector on outrigger models.

Operation Indicator Codes (OIC)

Lists OIC codes indicating machine status, not malfunctions.

Diagnostic Trouble Codes (DTC)

Explains types of DTCs (HXXX, PXXX, UXXX, FXXX, CXXX) indicating malfunctions.

Troubleshooting HXXX and PXXX Faults

Typical steps for diagnosing and fixing HXXX and PXXX faults.

Fault Inspection Procedure

Step-by-step procedure to inspect devices, harnesses, and ECM for faults.

Type HXXX Faults

Lists HXXX fault codes, messages, descriptions, causes, and failure modes.

Type FXXX Faults

Lists FXXX fault codes, messages, descriptions, causes, and failure modes.

Type PXXX Faults

Lists PXXX fault codes, messages, descriptions, causes, and failure modes.

Type UXXX Faults

Lists UXXX fault codes, messages, descriptions, causes, and failure modes.

Type CXXX Faults

Lists CXXX fault codes, messages, descriptions, causes, and failure modes.

Schematics

About This Section

Describes the two groups of schematics: electrical and hydraulic.

Electrical Schematics

Warnings and information about electrical schematics.

Hydraulic Schematics

Warnings and information about hydraulic schematics.

Electrical Component and Wire Color Legends

Legends for electrical components and wire colors used in schematics.

Electrical Component Legend (cont.)

Continued legend for electrical components.

Wire Color Legend

Legend for wire colors used in schematics.

Hydraulic Component Legend

Legend for hydraulic components used in schematics.

Electrical Symbols Legend

Explains common electrical symbols used in schematics.

Hydraulic Symbols Legend

Explains common hydraulic symbols used in schematics.

Limit Switch Legend

Identifies locations of various limit switches on the machine.

Charger Interlock

Explains the charger interlock circuit and its states.

Contactor Box Layout, All Models

Diagram showing the layout of components within the contactor box.

Ground Control Box Layout, All Models

Diagram showing the layout of components within the ground control box.

Platform Control Box Layout, All Models

Diagram showing the layout of components within the platform control box.

Generator Wiring Diagram, All Models

Wiring diagram for the generator system.

Electrical Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift, (ANSI; CSA)

Electrical schematic for specific models and lift types.

Electrical Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift, (ANSI; CSA)

Electrical schematic for specific models and lift types.

Electrical Schematic, GS-4069 BE with 2 Speed Lift, (ANSI; CSA)

Electrical schematic for specific models and lift types.

Electrical Schematic, GS-4069 BE with Proportional Lift, (ANSI; CSA)

Electrical schematic for specific models and lift types.

Electrical Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift, (AS; CE)

Electrical schematic for specific models and lift types.

Electrical Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift, (AS; CE)

Electrical schematic for specific models and lift types.

Electrical Schematic, GS-4069 BE with 2 Speed Lift, (AS; CE)

Electrical schematic for specific models and lift types.

Electrical Schematic, GS-4069 BE with Proportional Lift, (AS; CE)

Electrical schematic for specific models and lift types.

Hydraulic Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift

Hydraulic schematic for specific models and lift types.

Hydraulic Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift

Hydraulic schematic for specific models and lift types.

Hydraulic Schematic, GS-4069 BE with 2 Speed Lift

Hydraulic schematic for specific models and lift types.

Hydraulic Schematic, GS-4069 BE with Proportional Lift

Hydraulic schematic for specific models and lift types.

Terex Genie GS-3369 BE Specifications