This document is a Service and Repair Manual for Genie GS™-2669 DC, GS™-3369 DC, and GS™-4069 DC scissor lifts, with part number 1272220GT, Rev B, May 2021. It provides detailed information for qualified service professionals to troubleshoot and repair these machines.
Function Description:
The manual covers the repair procedures, fault codes, electrical schematics, and hydraulic schematics for the specified Genie scissor lift models. These machines are designed for lifting personnel and equipment to working heights, featuring DC electric power. They are classified as Group A/Type 3 according to ISO 16368, indicating their suitability for operation on firm, level surfaces with the platform in the stowed position for most maintenance procedures. The machines are equipped with various safety features and control systems to ensure safe operation and facilitate maintenance.
Important Technical Specifications:
Fluid Capacities:
- Hydraulic tank (maximum fill capacity): 16.5 gallons (62.5 liters)
- Hydraulic system (including tank): 18 gallons (68.1 liters)
- Drive hub: 24.5 ounces (725 cc) of EP 90 or SAE 90 multipurpose hypoid gear oil API service classification GL5.
Tires and Wheels:
- Wheel lugs: 9 @ 5/8-18
- Lug nut torque, dry (Rear): 170 ft-lbs (230 Nm)
- Lug nut torque, lubricated (Rear): 130 ft-lbs (176 Nm)
- Lug nut torque, dry (Front): 90 ft-lbs (122 Nm)
- Lug nut torque, lubricated (Front): 68 ft-lbs (92 Nm)
- Castle nut (steer end) torque: 35 ft-lbs (47.5 Nm)
- Non-marking, foam filled, RT tire size: 26 x 12D380
- Tire ply rating: 8
- Tire diameter: 26 inches (66 cm)
- Tire width: 12 inches (30 cm)
- Weight, each tire: 177.5 lbs (80.5 kg)
- 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)
- Drive speed, maximum (Platform stowed, Reverse direction): 3.0 mph (4.8 km/h), 40 ft / 9.1 sec (12.2 m / 9.1 sec)
- Drive speed, maximum (Platform raised): 0.3 mph (0.5 km/h), 40 ft / 91 sec (12.2 m / 91 sec)
- Braking distance, maximum (High range on paved surface): 3 ft (0.9 m)
- Gradeability: See Operator's Manual
- Function speed, maximum from platform controls (with maximum rated load in platform):
- GS-2669 DC (Platform up): 29 to 39 seconds
- GS-2669 DC (Platform down): 26 to 36 seconds
- GS-3369 DC (Platform up): 34 to 44 seconds
- GS-3369 DC (Platform down): 24 to 34 seconds
- GS-4069 DC (Platform up): 56 to 66 seconds
- GS-4069 DC (Platform down): 23 to 33 seconds
- Outrigger leveling, maximum (Front): 5.3°
- Outrigger leveling, maximum (Back): 4.2°
- Outrigger leveling, maximum (Side to side): 11.7°
Hydraulic Component Specifications:
- Function pump (Type): Gear pump
- Function pump (Displacement): 0.4 cu in (6 cc)
- Function pump (Flow rate @ 3100 rpm): 6 gpm (22.7 L/min)
- System relief valve pressure, maximum: 3500 psi (241 bar)
- Lift relief valve 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)
Battery Specifications:
- T105 (Type): 6V DC
- T105 (Quantity): 8
- T105 (Capacity): 225 AH
- T105 (Reserve capacity @ 25A rate): 447 minutes
- T105 (Reserve capacity @ 75A rate): 115 minutes
- T105 (Weight, each): 62 lbs (28 kg)
- T105 (Weight (tray with batteries)): 554 lbs (251 kg)
- J305GH (Type): 6V DC
- J305GH (Quantity): 8
- J305GH (Capacity): 315 AH
- J305GH (Reserve capacity @ 25A rate): 678 minutes
- J305GH (Reserve capacity @ 75A rate): 175 minutes
- J305GH (Weight, each): 88 lbs (40 kg)
- J305GH (Weight (tray with batteries)): 779 lbs (353.5 kg)
Usage Features:
The machines are operated from either ground controls or platform controls. The ground controls allow for machine setup, including adjusting function speed parameters, machine models, and options. The platform controls feature an Emergency Stop button, electronic circuit board, proportional control handle, drive/steer enable switch, alarm, function buttons, and an LED display. Operational Indicator Codes (OIC) on the platform controls LED readout indicate machine operating status (e.g., off-level, overload cutout, chassis mode). Diagnostic Trouble Codes (DTC) are also provided to pinpoint malfunctions in the electrical system.
Maintenance Features:
The manual emphasizes safety, requiring trained and qualified personnel for repairs, use of appropriate tools and lifting equipment, and adherence to safety rules. Key maintenance procedures covered include:
- Platform Controls: Removal and installation of the circuit board, joystick, alarm, and Emergency Stop button. Torque specifications for fasteners are provided.
- Platform Components: Procedures for removing the platform and platform extension deck, including warnings about crushing hazards and the need for overhead lifting devices.
- Scissor Components: Disassembly of the scissor assembly for GS-2669 DC, GS-3369 DC, and GS-4069 DC models, including removal of the platform, ladder, cables, lift cylinder, and linkage. Warnings about bodily injury from hydraulic oil and crushing hazards are highlighted.
- Wear Pads: Replacement of platform and chassis scissor arm slider blocks and wear pads.
- Lift Cylinders: Removal procedures for lift cylinders, noting that GS-2669 DC and GS-3369 DC use one, while GS-4069 DC uses two.
- Ground Controls: Procedures for determining software revision level, machine setup, auxiliary platform lowering, and installing/calibrating the level sensor (with and without outriggers). A Service Override Mode is available for troubleshooting.
- Hydraulic Pump: Testing, removal, and calibration procedures for the hydraulic pump.
- Manifolds: Identification of function manifold components, valve adjustments (system relief, oscillate relief, steer relief, platform up relief), and outrigger manifold components.
- Valve Coils: Testing procedures for valve coil resistance and diodes.
- Hydraulic Tank: Removal procedures for the hydraulic tank.
- Steer Axle Components: Removal of the yoke assembly, drive motor, tie rod, oscillate cylinder, and steer angle sensor. Procedures for testing oscillate axle hose routing and calibrating the steer angle sensor are also included.
- Non-steer Axle Components: Removal of drive motors and drive hubs.
- Outrigger Components: Removal of outrigger cylinders and outrigger calibration.
- Platform Overload Components: Calibration of the platform overload system and checking the maximum height limit switch. Troubleshooting for platform overload system issues and clearing overload recovery messages are also detailed.
The manual includes comprehensive diagnostic charts for "HXXX," "PXXX," "UXXX," "FXXX," and "CXXX" fault codes, along with wiring diagrams and component layouts to aid in troubleshooting. It also specifies torque values for hydraulic hose and fitting connections.
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