Genie Maintenance Manuals From SN 14-5000, 16F-7897, F-18000, M-101 Service Manual

Service and Repair Manual

Serial Number Range

GS™-2669 BE

from GS69F-18000

This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics

GS™-3369 BE

GS™-4069 BE

For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.

Original Instructions
Part No. 1306586GT
Rev A1
August 2022

Service and Repair Manual August 2022

Introduction

Introductio n Introductio n
Important Inf or matio n

Important

Read, understand and obey the safety rules
and operating instructions in the appropriate
Operator's Manual on your machine before
attempting any procedure.

This manual provides troubleshooting and
repair procedures for qualified service
professionals.

Basic mechanical, hydraulic and electrical
skills are required to perform most procedures.
However, several procedures require
specialized skills, tools, lifting equipment and a
suitable workshop. In these instances, we
strongly recommend that maintenance and
repair be performed at an authorized Genie
dealer service center.

Compliance

Technical Publications

Genie has endeavored to deliver the highest
degree of accuracy possible. However,
continuous improvement of our products is a
Genie policy. Therefore, product specifications
are subject to change without notice.

Readers are encouraged to notify Genie of
errors and send in suggestions for
improvement. All communications will be
carefully considered for future printings of this
and all other manuals.

Contact Us:

Internet: www.genielift.com
E-mail: [e-mail]

Find a Manual for this Model

Go to http://www.genielift.com

Machine Classification

Group A/Type 3 as defined by ISO 16368

Machine Design Life

Unrestricted with proper operation, inspection
and scheduled maintenance.

Use the links to locate Service Manuals,
Maintenance Manuals, Service and Repair
Manuals, Parts Manuals and Operator's
Manuals.

Copyright © 2020 by Terex Corporation

1306586GT Rev A, May 2021

Second Edition, First Printing

Genie is a registered trademark of Terex South Dakota,
Inc. in the U.S.A. and many other countries.

“GS” is a trademark of Terex South Dakota, Inc.

ii GS

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Section – Schematics, Legends and schematics

Introduction

Revision History

Revision History

Revision Date Section Procedure / Page / Description

A 5/2021

A1 8/2022 Fault Codes Update fault codes

Initial Release

Reference Examples:

Section – Repair Procedure, 4-2

Section – Fault Codes, All charts

Electronic Version

Click on any content or proc edure in the Table of Contents to view

the update.

Part No. 1306586GT GS

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-2669 BE • GS™-3369 BE • GS™-4069 BE iii

Service and Repair Manual August 2022

Introduction

Serial Number Legend

1 Model
2 Facility code
3 Sequence number

4 Serial label, ((located inside cover))
5 Serial number, ((stamped on chassis))

iv GS

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August 2022 Service and Repair Manual

Safety Rules

Section 1 Safety Rules

General Saf ety Rul es

Danger

Failure to obey the instructions and safety rules in
this manual and the appropriate Operator's Manual
on your machine will result in 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 modify or alter a MEWP without prior
written permission from the manufacturer.

Do Not Perform Maintenance
Unless:

 You are trained and qualified to perform

maintenance on this machine.

 You read, understand and obey:

• manufacturer's instructions and safety rules

• employer's safety rules and worksite

regulations

• applicable governmental regulations

 You have the appropriate tools, lifting

equipment and a suitable workshop.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:

Safety alert symbol
alert pers
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 avoided,
will result in death or serious
injury.

Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.

Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.

Indicates a potentially hazardous
situation which,
may result in property damage.

Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.

Be aware of potential crushing hazards
such as moving parts, free swinging or
unsecured
placing loads. Always wear approved
steel

Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases
and engine fuels. Always have an
approved fire extinguisher within easy
reach.

Be sure that all tools and workin
are properly maintained and ready for
use. Keep work surfaces clean and free
of debris that could get into machine
components and cause damage.

Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of suppor
weight to be lifted. Use only chains or
straps that are in good condition and of
ample capacity.

Be sure that fasteners intended for one
time use (i.e., cotter pins and self
nuts) are not reused. These components
may fai

Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe.

Be sure that your workshop or work area
is properly ventilated and well lit.

Safety Rules

Personal Safety

Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.

—used to

onnel to potential

Workplace Safety

Any person working on or around a machine must
be aware of all known safety hazards. Personal
safety and the continued safe operation of the
machine should be your top priority.

ting and stabilizing the

g areas

components when lifting or

-toed shoes.

vi GS

-locking

l if they are used a second time.

if not avoided,

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022

Table of Contents

Introduction Introduction ...................................................................................................... ii

Important Information ......................................................................................... ii

Find a Manual for this Model ............................................................................... ii

Revision History ................................................................................................ iii

Serial Number Legend ....................................................................................... iv

Section 1 Safety Rules ...................................................................................................... v

General Safety Rules ......................................................................................... v

Section 2 Specifications ................................................................................................... 1

Machine Specifications ....................................................................................... 1

Performance Specifications ................................................................................ 2

Hydraulic Oil Specifications ................................................................................ 2

Hydraulic Component Specifications ................................................................... 5

Manifold Component Specifications .................................................................... 5

Battery Specifications ......................................................................................... 6

Machine Component Weights ............................................................................. 6

Kohler KD350 Engine Specifications ................................................................... 7

Hydraulic Hose and Fitting Torque Specifications ............................................... 8

Torque Procedure .............................................................................................. 9

Part No. 1306586GT GS

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August 2022

Table of Contents

Section 3 Repair Procedures ......................................................................................... 11

Introduction ...................................................................................................... 11

Platform Controls ........................................................................................... 13

1-1 Circuit Board .............................................................................................. 14

1-2 Joystick ...................................................................................................... 15

1-3 Platfrom Controls Alarm ............................................................................. 15

1-4 Platfrom Emergency Stop Button................................................................ 16

Platform Components .................................................................................... 17

2-1 Platform ..................................................................................................... 17

2-2 Platform Extension Deck ............................................................................ 18

Scissor Components ..................................................................................... 20

3-1 Scissor Assembly, GS-2669 BE ................................................................. 21

3-2 Scissor Assembly, GS-3369 BE ................................................................. 24

3-3 Scissor Assembly, GS-4069 BE ................................................................. 28

3-4 Wear Pads ................................................................................................. 31

3-5 Lift Cylinders .............................................................................................. 33

3-6 Height Angle Sensor .................................................................................. 35

How to Replace the Height Angle Sensor .................................................... 35

Engines........................................................................................................... 36

4-1 Oil Pressure Switch .................................................................................... 36

How to Replace the Oil Pressure Switch ...................................................... 36

How to Repair the Kohler KD350 Engine .......................................................... 36

viii GS

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August 2022

Table of Contents

Ground Controls ............................................................................................. 37

5-1 Software Revision Level ............................................................................. 38

5-2 Machine Setup ........................................................................................... 39

5-3 Auxiliary Platform Lowering ........................................................................ 40

5-4 Level Sensor - Models without Outriggers ................................................... 40

5-5 Level Sensor - Models with Outriggers ........................................................ 43

5-6 Service Override Mode ............................................................................... 45

Hydraulic Pump .............................................................................................. 47

6-1 Hydraulic Pump .......................................................................................... 47

How to Test the Hydraulic Pump .................................................................. 47

How to Remove the Hydraulic Pump............................................................ 47

How to Calibrate the Hydraulic Pump........................................................... 48

Manifolds ........................................................................................................ 51

7-1 Function Manifold Components .................................................................. 51

7-1a Function Manifold Components - Models with Proportional Relief

(from serial number GS6916F-10015) ....................................................... 52

7-2 Valve Adjustments - Function Manifold ....................................................... 55

How to Adjust the System Relief Valve ........................................................ 55

How to Adjust the Oscillate Relief Valve ...................................................... 57

How to Adjust the Steer Relief Valve............................................................ 59

How to Adjust the Platform Up Relief Valve -

Models with Platform Overload ............................................................. 61

7-3 Outrigger Manifold Components ................................................................. 71

7-4 Valve Coils ................................................................................................. 72

Fuel and Hydraulic Tanks .............................................................................. 74

8-1 Fuel Tank ................................................................................................... 74

8-2 Hydraulic Tank ........................................................................................... 75

Part No. 1306586GT GS

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August 2022

Table of Contents

Steer Axle Components ................................................................................. 76

9-1 Yoke Assembly .......................................................................................... 76

9-2 Steer Cylinder ............................................................................................ 78

9-3 Tie Rod ...................................................................................................... 78

9-4 Oscillate Cylinder ....................................................................................... 79

9-5 Oscillate Hoses .......................................................................................... 79

9-6 Steer Angle Sensor .................................................................................... 81

Non-steer Axle Components ......................................................................... 86

10-1 Drive Motors ............................................................................................ 86

10-2 Drive Hub ................................................................................................. 87

Outrigger Components .................................................................................. 88

11-1 Outrigger Cylinder .................................................................................... 88

11-2 Outrigger Calibration ................................................................................ 89

Platform Overload Components .................................................................... 91

How to Calibrate the Platform Overload System .......................................... 91

12-2 Platform Overload Recovery..................................................................... 93

12-3 Down Limit Height .................................................................................... 95

How to Calibrate the Down Limit Height ...................................................... 95

Battery Charger .............................................................................................. 96

13-1 Battery Charger ........................................................................................ 96

x GS

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August 2022

Table of Contents

Section 4 Fault Codes ..................................................................................................... 98

Introduction ...................................................................................................... 98

Platform Overload Fault Codes.................................................................... 101

GCON I/O Map ............................................................................................... 106

Operation Indicator Codes (OIC) .................................................................... 108

Diagnostic Trouble Codes (DTC) .................................................................... 108

Troubleshooting "HXXX" and "PXXX" Faults ................................................... 109

Fault Inspection Procedure ............................................................................. 110

Type "HXXX" Faults ....................................................................................... 112

Type "PXXX" Faults ........................................................................................ 115

Type "UXXX" Faults ....................................................................................... 118

Type "FXXX" Faults ........................................................................................ 120

Type "CXXX" Faults ....................................................................................... 123

Part No. 1306586GT GS

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August 2022

Table of Contents

Section 5 Schematics ................................................................................................... 125

Introduction .................................................................................................... 125

Electrical Component and Wire Color Legends ............................................... 126

Hydraulic Component Legend ........................................................................ 130

Electrical Symbols Legend ............................................................................. 131

Hydraulic Symbols Legend ............................................................................. 132

Limit Switch Legend ....................................................................................... 133

Charger Interlock ........................................................................................... 134

Control Boxes and Options ......................................................................... 135

Contactor Box Layout, All Models ................................................................... 136

Ground Control Box Layout ............................................................................ 137

Platform Control Box Layout, All Models ......................................................... 140

Schematic, Generator Option GS-69 BE ........................................................ 141

Electrical Schematics .................................................................................. 143

Electrical Schematic 1, GS-69 BE .................................................................. 144

Electrical Schematic 2, GS-69 BE .................................................................. 145

Hydraulic Schematics .................................................................................. 147

Hydraulic Schematic, GS-69 BE ..................................................................... 148

xii GS

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August 2022 Service and Repair Manual

Fluid capacities

Hydraulic tank
(maximum fill

allons

iters

Hydraulic system (including tank)

allons

iters

Drive hub
EP 9
gear oil API service classification GL5

unces

c

Fuel tank

allons

iters

Tires and wheels

Wheel lugs (steer end)

18

Lug nut torque, dry

lbs

122 Nm

Lug nut torque, lubricated

lbs

92 Nm

Wheel lugs (non

18

Lug nut torque, dry

lbs

230 Nm

Lug nut torque, lubricated

lbs

176 Nm

Castle nut (steer end)

Castle nut torque

lbs

47.5 Nm

Non-marking, foam filled, RT

Tire size

26 x 12D380

Tire ply rating

8

Tire diameter

n

m

Tire width

n

m

Weight, each

bs

g

Specifications

Section 2 Specificatio ns

Machine Specifi c atio ns

Machine Specifications

capacity)

18 g

0 or SAE 90 multipurpose hypoid

-steer end)

16.5 g

62.5 l

68.1 l

24.5 o
725 c

3.3 g

12.5 l

9 @ 5/8-

90 ft-

68 ft-

9 @ 5/8-

170 ft-

For operational specifications, refer to the
Operator's Manual.

26 i

66 c

12 i

30 c

177.5 l

80.5 k

130 ft-

35 ft-

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Drive speed, maximum

Platform stowed
Forward direction

ph

m/h

ec

12.2 m / 6.1 sec

Platform stowed
Reverse direction

ph

m/h

ec
ec

Platform raised

ph

m/h

ec
ec

Braking distance, maximum

High range on paved
surface

t

m

Gradeability

See Operator's Manual

Function speed, maximum from platform controls
(with maximum rated load in platform)

Platform up
Platform down

econds
econds

GS-3369 BE

Platform up
Platform down

econds
econds

GS-4069 BE

Platform up
Platform down

econds

23 - 33seconds

Outrigger leveling, maximum

Front
Back
Side to side

5.3°

4.2°

11.7°

Hydraulic Fluid Specifications

Genie specifications require hydraulic oils which are
designed to give maximum protection to hydraulic
systems, have the ability to perform over a wide
temperature range, and the viscosity index should
exceed 140. They should provide excellent antiwear,
oxidation prevention, corrosion inhibition, seal
conditi
properties.

Cleanliness level,
minimum

ISO 15/13

Water content,
maximum

pm

Recommended Hydraulic Fluid

Hydraulic oil type

Chevron Rando HD Premium

ISO Grade

32

Viscosity index,
maximum

Optional Hydraulic Fluids

Mineral based

Shell Tellus S2 V 32
Shell Tellus S2 V 46

Shell Tellus S4 VX 32

Shell Donax TG (Dexron III)

Chevron 5606A

Biodegradable

46

Fire resistant

5046

Optional fluids may not have
the same hydraulic lifespan and
may result in component
damage.

Specifications

Performance S peci f icati o ns

Performance Specifications

40 ft / 6.1 s

4.5 m

7.2 k

Hydraulic Oi l Spec ific ations

Hydraulic Oil Specifications

GS-2669 BE

12.2 m / 9.1 s

29 to 39 s

26 - 36 s

34 to 44 s

24 - 34 s

56 to 66 s

3.0 m

4.8 k

40 ft / 9.1 s

0.3 m

0.5 k

40 ft / 91 s

12.2 m / 91 s

less than 3 f

less than 0.9

oning, and foam and aeration suppression

250 p

200

Petro Canada Environ MV

UCON Hydrolube HP-

Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie
Product Support before use.

2 GS

Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond its
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Do not top off with incompatible
hydraulic fluids. Hydraulic fluids
may be incompatible due to the
differences in base additive
chemistry. When incompatible
fluids are mixed, insoluble
materials may form and deposit
in the hydraulic system,
plugging hydraulic lines, filt
control valves and may result in
component damage.

ISO Grade

32

Viscosity index, maximum

200

Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C

7.5

33.5

Brookfield Viscosity, maximum
cP @
cP @

1040
3310

Flash point

375°F / 190°C

Pour point

50°C

Maximum continuous operating
temperature

171°F / 77°C

Specifications

Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.

Hydraulic Fluid Temperature
Range

ers,

Chevron Rando HD Premium Oil
MV Fluid Properties

-4°F / -20°C

-22°F / -30°C

Note: A hydraulic oil heating system is
recommended when the ambient temperature is
consistently below 0°F / -18°C.

Note: Do not operate the machine when the
ambient temperature is below -20°F / -29°C with
Rando HD Premium MV.

-58°F / -

1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV

Part No. 1306586GT GS

Ambient air temperature

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Service and Repair Manual August 2022

ISO Grade

15

Viscosity index,

300

Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
cSt @

5.5

15.0
510

Flash point

180°F / 82°C

Pour point

-81°F / -63°C

Maximum continuous operating
temperature

124°F / 51°C

Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
abo
component damage

ISO Grade

46

Viscosity index, maximum

154

Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C

8.0

44.4

Flash point

482°F / 250°C

Pour point

45°C

Maximum continuous operating
temperature

180°F / 82°C

ISO Grade

32

Viscosity index, maximum

300

Kinematic Viscosity, maximum
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C

9

33.8

Brookfield
cSt @
cSt @
cSt @

481

702.4
2624

Flash point

>100

Pour point

60°C

Maximum continuous operating
temperature

103°F / 75°C

ISO Grade

46

Viscosity index, maximum

192

Kinematic Viscosity, maximum
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F / -18°C

22
46

1300

Flash point

None

Pour point

63°C

Maximum continuous operating
temperature

189°F / 87°C

Specifications

Chevron 5606A Hydraulic Oil
Fluid Properties

Shell Tellus S4 VX Fluid
Properties

maximum

-40°F / -40°C

Note: 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.

ve 32°F / 0°C may result in

Petro-Canada Environ MV 46
Fluid Properties

-49°F / -

Viscosity, maximum

-4°F / -20°C

-13°F / -25°C

-40°F / -40°C

-76°F / -

UCON Hydrolube HP-5046 Fluid
Properties

-81°F / -

4 GS

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Drive Pump

Type

gear pump

Displacement

u in

c

Flow rate @ 310

pm

22.7 L/min

System relief valve pressure,
maximum

s

ari

Lift relief valve
GS

si

ar

Lift relief valve pressure
GS

si

ar

Lift relief valve pressure
GS

si

ar

Steer relief valve pressure

si

103 bar

Oscillate relief valve pressure

si

ar

Steer flow regulator

pm

7.6 L/min

Oscillate flow regulator

pm

4 L/min

Plug torque

SAE No. 2

lbs / 4 Nm

SAE No. 4

10 ft-lbs / 13 Nm

SAE No. 6

lbs / 19 Nm

SAE No. 8

lbs / 51 Nm

SAE No.10

lbs / 55 Nm

SAE No. 12

lbs / 76 Nm

Specifications

Hydraulic Com pon ent S p ecif icati ons

Hydraulic Component
Specifications

Manifold Co mpo nent Spec ific a tions

Manifold Component
Specifications

0 rpm

Function manifold

pressure

-2669 BE

-3369 BE

-4069 BE

0.4 c

6 g

3500 p
241 b

3100 p

214 b

3300 p

1 g

2900 p

200 b

2850 p

197 b

1500 p

228 b

2 g

6 c

36 in-

14 ft-

38 ft-

41 ft-

56 ft-

Part No. 1306586GT GS

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Service and Repair Manual August 2022

T105

Type

6V DC

Quantity

8

Capacity

225 AH

Reserve capacity @ 25A rate

inutes

Reserve capacity @ 75A rate

inutes

Weight, each

g

Weight (tray with batteries)

g

T145

Type

6v DC

Quantity

8

Capacity

260 AH

Reserve capacity @ 25A rate

inutes

Reserve capacity @ 75A rate

inutes

Weight, each

72 lbs / 33 kg

Weight (tray with batteries)

g

Platform assembly

bs

425 kg

Link assembly (GS

bs

g

Link assembly (GS

bs

g

Link assembly (GS

bs

g

Outrigger assembly (if equipped)

bs

g

Chassis assembly (GS
(T10

bs

g

Chassis assembly (GS
(T10

bs

g

Chassis assembly (GS
(T14

bs

3411 kg

Chassis assembly (GS
(T14

bs

2463 kg

Chassis assembly (GS
(T14

bs

g

Specifications

Battery Speci ficat i ons

Battery Specifications

Machine Co mponent Weight s

Machine Component Weights

936 l

447 m

115 m

-4069)

-3369)

-2669)

63 lbs / 29 k

504 lbs / 229 k

-3369)

5 battery option)

5 battery option)

530 m

145 m

5 battery option)

5 battery option)

576 lbs / 261 k

5 battery option)

-2669)

-4069)

-3369)

-2669)

3430 l

1556 k

2607 l

1183 k

2156 l

978 k

850 l

386 k

5342 l

2423 k

6053 l

2746 k

7521 l

5430 l

6141 l

2786 k

6 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Displacement

u in

iters

Number of cylinders

1

Bore and Stroke

nches

m

Horsepower

pm

W

High idle

pm

Compression ratio

20.3:1

Oil pressure (@ 200

si

ar

Oil capacity

uarts

iters

Units ship with 15W-40.

Extreme operating temperatures may require the use of
alternative engine oils. For oil requirements, refer to the
Engine Operator Handbook on your machine.

Oil Pressure switch

Oil pressure switch point

si

1 to 1.5 bar

Fuel injection system

Injection pump

Direct

For fuel requirements, refer to the engine Operator
Manual for your engine.

Battery

Type

12V DC

Group

U1R

Quantity

1

Ampere hour

33

Cold cranking ampere

330

Reserve capacity @ 25A rate

inutes

Specifications

Kohler KD350 E ngi ne S p ecif icati ons

Kohler KD350 Engine

21.3 c

Lubrication system

0 rpm) 40 to 60 p

(including filter)

Oil viscosity requirements

0.4 l

3.3 x 2.6 i
82 x 66 m

6.7 @ 3600 r
5 k

3600/3000 r

1.4 to 3 b

1.3 q

1.2 l

Fuel requirement

45 m

14.5 to 21.8 p

Part No. 1306586GT GS

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-2669 BE • GS™-3369 BE • GS™-4069 BE 7

Service and Repair Manual August 2022

SAE Dash Size

Torque

-8

40 ft-lbs / 55 Nm

SAE Dash Size

Thread Size

Flats

-16

1 5/16-12

1

SAE Dash Size

Torque

-8

36 ft-lbs / 49 Nm

-4

ORFS / 37° (Adj)

-6

ORFS (Adj / Non-adj)

-16

(All types)

-20

(All types)

Specifications

Hydraulic Hos e and Fitti ng Tor que S p ecifi cati ons

Hydraulic Hose and Fitting
Torque Specifications

Your machine is equipped with Parker Seal-Lok™
ORFS or 37° JIC fittings and hose ends. Genie
specifications require that fittings and hose ends
be torqued to specification when they are removed
and installed or when new hoses or fittings are
installed.

Seal-Lok™ Fittings

(hose end - ORFS)

-4 18 ft-lbs / 25 Nm

-6 30 ft-lbs / 41 Nm

-10 60 ft-lbs / 81 Nm

-12 85 ft-lbs / 115 Nm

-16 110 ft-lbs / 150 Nm

-20 150 ft-lbs / 205 Nm

-24 230 ft-lbs / 315 Nm

SAE O-ring Boss Port

(tube fitting - installed into Aluminum)

(all types)

-4 14 ft-lbs / 19 Nm

-6 23 ft-lbs / 31,2 Nm

-10 62 ft-lbs / 84 Nm

-12 84 ft-lbs / 114 Nm

-16 125 ft-lbs / 169,5 Nm

-20 151 ft-lbs / 204,7 Nm

-24 184 ft-lbs / 249,5 Nm

Adjustable Fitting Non-adjustable fitting

1 jam nut

JIC 37° Fittings

(swivel nut or hose connection)

-4 7/16-20 2

-6 9/16-18 1 1/2

-8 3/4-16 1 1/2

-10 7/8-14 1 1/2

-12 1 1/16-12 1 1/4

-20 1 5/8-12 1

-24 1 7/8-12 1

SAE O-ring Boss Port

(tube fitting - installed into Steel)

SAE Dash Size Torque

15 ft-lbs / 20,3 Nm
ORFS (Non-adj)
37° (Non-adj)

37° (Adj / Non-adj)

ORFS (Adj / Non-adj)

-8
37° (Adj / Non-adj)

-10 ORFS (Adj / Non-adj)
37° (Adj / Non-adj)

-12 (All types)

-24 (All types)

26 ft-lbs / 35,3 Nm

22 ft-lbs / 30 Nm

35 ft-lbs / 47,5 Nm
29 ft-lbs / 39,3 Nm

60 ft-lbs / 81,3 Nm
52 ft-lbs / 70,5 Nm

100 ft-lbs / 135,6 Nm

85 ft-lbs / 115,3 Nm

135 ft-lbs / 183 Nm

200 ft-lbs / 271,2 Nm

250 ft-lbs / 339 Nm

305 ft-lbs / 413,5 Nm

8 GS

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August 2022 Service and Repair Manual

Specifications

Torque Proce dur e

Torque Procedure

Seal-Lok™ fittings

1 Replace the O-ring. The O-ring must be

replaced anytime the seal has been broken.
The O-ring cannot be re-used if the fitting or
hose end has been tightened beyond finger
tight.

Note: The O-ring in Parker Seal Lok™ fittings and
hose end are custom-size O-rings. They are not
standard size O-rings. They are available in the O­ring field service kit (Genie part number 49612).

2 Lubricate the O-ring before installation.

3 Be sure the O-ring face seal is seated and

retained properly.

JIC 37° fittings

1 Align the tube flare (hex nut) against the nose

of the fitting body (body hex fitting) and
tighten the hex nut to the body hex fitting to
hand tight, approximately 30 in-lbs / 3.4 Nm.

2 Using a permanent ink marker, make a

reference mark on one the flats of the hex nut
and continue the mark onto the body of the
hex fitting. Refer to Illustration 1.

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

torque. Refer to the appropriate torque chart
in this section.

6 Operate all machine functions and inspect the

hose, fittings and related components to
confirm there are no leaks.

Illustration 1

1 hex nut
2 reference mark
3 body hex fitting

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Specifications

3 Working clockwise on the body hex fitting,

make a second mark with a permanent ink
marker to indicate the proper tightening
position. Refer to Illustration 2.

Note: Use the JIC 37° Fitting table in this section
to determine 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 tighten the
joint after it has been loosened.

Illustration 2

1 body hex fitting
2 reference mark
3 second mark

4 Tighten the hex nut until the mark on the hex

nut is aligned with the second mark on the
body hex fitting.

5 Operate all machine functions and inspect the

hose, fittings and related components to
confirm there are no leaks.

10 GS

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August 2022 Service and Repair Manual

Repair Procedures

Section 3 Repair Proce dur es

Introductio n

Observe and Obey:

 Repair procedures shall be completed by a

person trained and qualified on the repair of
this machine.

 Immediately tag and remove from service a

damaged or malfunctioning machine.

 Repair any machine damage or malfunction

before operating the machine.

Before Repairs Start:

 Read, understand and obey the safety rules

and operating instructions in the appropriate
operator's manual on your machine.

Machine Configuration:

 Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:

• Machine parked on a firm, level surface

• Key switch in the off position with the key

removed

• The red Emergency Stop button in the off
position at both the ground and platform
controls

• Wheels chocked

• All external AC power supply disconnected

from the machine

• Platform in the stowed position

 Be sure that all necessary tools and parts are

available and ready for use.

 Use only Genie approved replacement parts.
 Read each procedure completely and adhere

to the instructions. Attempting shortcuts may
produce hazardous conditions.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all sa
messages that follow this symbol
to avoid possible injury or death.

Indicates a imminently hazardous
situation which, if not avoided, will
result in death or serious injury.

Indicates a potentially hazardous
situation which, if not avoided,
coul
injury.

Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.

Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.

Repair Procedures

About This Section

Most of the procedures in this section should only
be performed by trained service professional in a
suitably equipped workshop. Select the
appropriate repair procedure after troubleshooting
the problem.

Symbols Legend

fety

Perform disassembly procedures to the point
where repairs can be completed. Then to re­assemble, perform the disassembly steps in
reverse order.

d result in death or serious

Indicates that a specific result is expected

after performing a series of steps.

Indicates that an incorrect result has occurred

after performing a series of steps.

12 GS

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August 2022 Service and Repair Manual

Code

Condition

LL Off

OL Platform Overload

CH Chassis Mode Operation

nd No Drive (option)

F053

DCON RR Thermal Protection

F054

DCON LR Thermal Protection

Ld Lifting Disabled (option)

St Engine Start Delay

Platform Controls

Platfor m C on tr ols

Platform controls

The platform controls are used to operate the
machine from the platform.

Activating a function button sends a signal to the
Electronic Control Module (ECM). When the ECM
is in the function mode, the platform controls are
used to operate the various machine functions.

The platform controls consist of an Emergency
Stop button, electronic circuit board, proportional
control handle, drive/steer enable switch, alarm,
function buttons and LED display.

For further information or assistance, contact
Genie Product support.

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 LED readout if a condition such
as off-level, overload cutout, chassis mode
operation or pothole guards stuck occurs. These
codes are not indicators of a device malfunction in
the electrical system.

If the platform controls LED readout displays an
operational indicator code such as LL, the fault
condition must be repaired or removed before
resuming machine operation. Push in and pull out
the red Emergency Stop button to reset the
system.

Platform Controls LED Readout

-Level

1 red Emergency Stop button P2
2 platform controls circuit board U3
3 proportional control handle and drive/steer

enable switch JC9

4 alarm H1

Note: A code and a description of a code can also
be viewed at the ground controls LCD display.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Electrocution/burn hazard.
Contact 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 board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.

Circuit board fastener torque specifications

Hand tighten until screw seats

lbs

< 0.6 Nm

Platform Controls

1-1 Circuit Bo ard

1-1
Circuit Board

8 Carefully disconnect all wire harness

connectors from the platform controls circuit
board.

How to Remove the Platform
Controls Circuit Board

1 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Remove the ties securing the wire harness.

6 Disconnect the red and black wires from the

alarm.

7 Carefully remove the alarm from the platform

control box.

9 Carefully remove the platform controls circuit

board fasteners.

10 Carefully remove the platform controls circuit

board from the platform control box.

11 Remove the transparent caps from the

platform controls circuit board and save.

14 GS

< 5 in-

Note: Before installing a circuit board, place the
transparent caps removed in step 11, over the
circuit board buttons.

Note: After installing the circuit board, check for
proper button operation. Excessive torque of the
circuit board fasteners will cause the buttons to
bind. Moderate torque of the circuit board
fasteners will not allow the buttons to engage.

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August 2022 Service and Repair Manual

Electrocution/burn hazard.
Contact with electrically charged
circuits could result in deat
serious injury. Remove all rings,
watches and other jewelry.

Component damage hazard.
Electrostatic discharge (ESD)
can damage printed circuit board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.

Torque specifications

Joystick fasteners

lbs

1 Nm

Electrocution/burn hazard.
Contact 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 board
compo
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.

Platform Controls

1-2 Joystick

1-2
Joystick

1-3 Platfro m Con trol s Al arm

1-3
Platform Controls Alarm

How to Remove the Joystick

1 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Remove the ties securing the joystick wire

harness.

6 Carefully disconnect the joystick wire harness

from the platform controls circuit board.

h or

How to Remove the Platform
Controls Alarm

1 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Disconnect the red and black wires from the

alarm.

nents. Maintain firm

7 Carefully remove the joystick fasteners.

8 Carefully remove the joystick from the

platform control box.

Part No. 1306586GT GS

6 Carefully remove the alarm from the platform

control box.

™

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9 in-

Service and Repair Manual August 2022

Electrocution/burn hazard.
Contact 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 board
components. Maintain firm
contact with a metal part of the
machine that is grounded at all
times when handling printed
circuit boards OR use a
grounded wrist strap.

Platform Controls

1-4 Platfrom E me rgenc y St o p Butt on

1-4
Platform Emergency Stop Button

How to Remove the Platform
Controls Emergency Stop Button

1 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls.

2 Disconnect the platform controls from the

control cable at the platform.

3 Remove the fasteners securing the platform

control box to the platform control bracket.

4 Remove the fasteners securing the bottom

cover to the platform control box. Open the
control box.

5 Disconnect the white wires from the

Emergency Stop base.

6 Carefully remove the Emergency Stop base

from the Emergency Stop button.

7 Carefully remove the retaining ring from the

Emergency Stop button.

8 Carefully remove the Emergency Stop button

from the platform control box.

16 GS

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August 2022 Service and Repair Manual

Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these
skills and tools could result in
death or serious injury and
significant component damage.
Dealer servi
recommended.

Component damage hazard. Be
sure not to cut the power to the
platform wiring.

Component damage hazard.
The platform controls wiring can
be damaged if it is kinked or
pinched.

Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

Platform Components

Platfor m C ompo ne nts

2-1 Platform

2-1
Platform

How to Remove the Platform

ce is strongly

Note: This procedure will require an overhead
supporting device capable of supporting 1000 lbs /
454 kg.

1 Remove the cable ties that secures the power

to platform wiring to the bottom of the
platform.

5 Remove the cover from the AC outlet. Tag

and disconnect the wiring from the outlet.

6 Models with air line to platform option:

Disconnect the air line from the platform. Pull
the air line free of the platform.

7 Attach a sling chain from the overhead lifting

device to the four lifting points on the platform.

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 Remove the platform controls from the

platform.

Part No. 1306586GT GS

8 Remove the two carriage bolts that secure the

platform to the platform pivot at the steer end
of the machine.

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Service and Repair Manual August 2022

Crushing hazard. The platform
will become unbalanced and fall
it not properly supported.

Platform Components

9 Carefully lift the platform enough to clear the

platform pivot.

10 Slide the platform towards the non-steer end

of the machine until the slider blocks are
visible underneath the slider block channel.

11 Carefully lift the platform off of the machine

and place it on a structure capable of
supporting it.

2-2 Platform E xten si on D eck

2-2
Platform Extension Deck

How to Remove the Platform
Extension Deck

1 Remove the retaining fasteners from the deck

catch and remove the deck catch.

2 Remove the retaining fasteners from the deck

stop and remove the deck stop.

3 Repeat steps 1 and 2 for the other side of the

platform.

Note: Note the position of the slider blocks before
the platform is removed so that when the platform
is installed they will be in the correct position.

1 deck catch
2 deck stop

4 Remove the platform controls from the

platform.

18 GS

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August 2022 Service and Repair Manual

Crushing hazard. The platform
extension will become
unbalanced and fall when
removed from the machine if not
properly supported and secured
to the

Platform Components

5 Release the four rail spacers by pulling the

retaining pin and turn them in a downward
position.

1 rail spacer

6 Position a forklift at the steer end of the

machine with the forks even with the bottom
of the platform extension.

9 Carefully slide the platform extension out and

away from the platform and place it on a
structure capable of supporting it.

forklift.

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 the forklift to support the
platform extension deck.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Scissor Components

Scissor C omp one nt s

Steer End

1 Platform pivot
2 Number 3 outer arm
3 Lift cylinder rod-end pivot pin
4 Number 3 pivot pin (steer end)
5 Number 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

20 GS

Non-steer End

10 Chassis pivot
11 Slider block (Qty. 2)
12 Number 3 inner arm
13 Number 3 center pivot pin (Qty. 2)
14 Number 3 pivot pin (non-steer end)
15 Number 2 inner arm
16 Number 2 outer arm
17 Number 2 pivot pin (non-steer end)
18 Lift cylinder barrel-end pivot pin

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

19 Number 1 outer arm

August 2022 Service and Repair Manual

Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these
skills and tools could result in
death or serious injury and
significant component damage.
D
recommended.

Component damage hazard.
Cables can be damaged if they
are kinked or pinched.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supported when
remove

Crushing hazard. The linkage
assembly could
unbalanced and fall if not
properly supported when
removed from the machine.

Scissor Components

3-1 Scissor Assembly, GS-2669 B E

3-1
Scissor Assembly, GS-2669 BE

4 Using a suitable supporting device, attach a

strap to the rod end of the lift cylinder. Do not
apply pressure.

How to Disassemble the Scissor
Assembly

ealer service is strongly

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

Note: This procedure will require an overhead
supporting device capable of supporting 1000 lbs /
454 kg.

1 Remove the platform. Refer to Repair

Procedure, How to Remove the Platform.

2 Remove the retaining fasteners that attach

the ladder to the drive chassis. Remove the
ladder and set aside.

5 Remove the lift cylinder rod end pivot pin

retaining fasteners.

6 Using a soft metal drift, remove the pivot pin.

7 Lower the lift cylinder and remove the strap.

8 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
3 inner arm. Make the chains tight but do not
apply lifting pressure.

d from the machine.

9 Remove the retaining fasteners from the

number 3 pivot pins.

Note: Do not remove the external snap ring.

10 Using a soft metal drift, remove the pivot pins

and set aside.

11 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

12 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
2 inner arm. Make the chains tight but do not
apply lifting pressure.

3 Remove the cables from the linkage

assembly.

Part No. 1306586GT GS

become

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Service and Repair Manual August 2022

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Crushing hazard. The linkage
assembly could become
unb
properly supported when
removed from the machine.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supported when
removed from the machine.

Scissor Components

13 Remove the retaining fasteners from the

number 2 pivot pins.

Note: Do not remove the external snap ring.

14 Using a soft metal drift, remove the pivot pins

and set aside.

15 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

16 Tag and disconnect the harness from the lift

cylinder valve block.

17 Tag and disconnect the hydraulic hoses from

the lift cylinder. Plug the hoses and cap the
fittings.

20 Remove the two carriage bolts that secure the

inner arm and chassis pivot to the steer end
of the drive chassis.

21 Move the linkage towards the non-steer end

of the machine until the slider feet are clear of
the slider channel.

22 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

Separate the link sets:

1 Using an overhead supporting device attach a

4 hook sling chain to the ends of the inner
arm. Make the chains tight but do not apply
lifting pressure.

18 Remove the hose clamps and hoses from the

number 1 inner arm.

19 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
1 inner arm. Make the chains tight but do not
apply lifting pressure.

alanced and fall if not

2 Remove the retaining fasteners from the

center pivot pins.

Note: Do not remove the external snap ring.

3 Using a soft metal drift, remove the center

pivot pins and set aside.

4 Carefully lift and separate the linkage

assembly apart and place it on a structure
capable of supporting it.

22 GS

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August 2022 Service and Repair Manual

Scissor Components

Steer End

1 Platform pivot
2 Number 4 center pivot pin (Qty. 2)
3 Number 4 pivot pin (steer end)
4 Number 3 center pivot pin (Qty. 2)
5 Lift cylinder rod-end pivot pin
6 Number 3 pivot pin (steer end)
7 Number 2 center pivot 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 pivot
14 Slider block (Qty. 2)
15 Number 4 inner arm
16 Number 4 outer arm
17 Number 4 pivot pin (non-steer end)
18 Number 3 inner arm
19 Number 3 outer arm
20 Number 3 pivot pin (non-steer end)
21 Number 2 inner arm
22 Number 2 outer arm
23 Number 2 pivot pin (non-steer end)
24 Lift cylinder barrel-end pivot pin
25 Number 1 outer arm

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attemptin
this procedure without these
skills and tools could result in
death or serious injury and
significant component damage.
Dealer service is strongly
recommended.

Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly suppor
removed from the machine.

Crushing hazard. The
assembly could become
unbalanced and fall if not
properly supported when
removed from the machine.

Scissor Components

3-2 Scissor Assembly, GS-3369 B E

3-2
Scissor Assembly, GS-3369 BE

How to Disassemble the Scissor
Assembly

4 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
4 inner arm. Make the chains tight but do not
apply lifting pressure.

g

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

Note: This procedure will require an overhead
supporting device capable of supporting 1000 lbs /
454 kg.

1 Remove the platform. Refer to Repair

Procedure, How to Remove the Platform.

2 Remove the retaining fasteners that attach

the ladder to the drive chassis. Remove the
ladder and set aside.

ted when

5 Remove the retaining fasteners from the

number 4 pivot pins.

Note: Do not remove the external snap ring.

6 Using a soft metal drift, remove the pivot pins

and set aside.

7 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

8 Using a suitable supporting device, attach a

strap to the rod end of the lift cylinder. Do not
apply pressure.

9 Remove the lift cylinder rod end pivot pin

retaining fasteners

10 Using a soft metal drift, remove the pivot pin.

11 Lower the lift cylinder and remove the strap.

12 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
3 inner arm. Make the chains tight but do not
apply lifting pressure.

3 Remove the cables from the linkage

assembly.

24 GS

linkage

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supported when
removed from the machine.

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to di
gradually. Do not allow oil to
squirt or spray.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supported when
removed from the machine.

Scissor Components

13 Remove the retaining fasteners from the

number 3 pivot pins.

Note: Do not remove the external snap ring.

21 Tag and disconnect the hydraulic hoses from

the lift cylinder. Plug the hoses and cap the
fittings.

14 Using a soft metal drift, remove the pivot pins

and set aside.

15 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

16 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
2 inner arm. Make the chains tight but do not
apply lifting pressure.

17 Remove the retaining fasteners from the

number 2 pivot pins.

Note: Do not remove the external snap ring.

18 Using a soft metal drift, remove the pivot pins

and set aside.

19 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

20 Tag and disconnect the harness from the lift

cylinder valve block.

ssipate

22 Remove the hose clamps and hoses from the

number 1 inner arm.

23 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
1 inner arm. Make the chains tight but do not
apply lifting pressure.

24 Remove the two carriage bolts that secure the

inner arm and chassis pivot to the steer end
of the drive chassis.

25 Move the linkage towards the non-steer end

of the machine until the slider feet are clear of
the slider channel.

26 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

Part No. 1306586GT GS

™

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Service and Repair Manual August 2022

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supported
removed from the machine.

Scissor Components

Separate the link sets:

1 Using an overhead supporting device attach a

4 hook sling chain to the ends of the inner
arm. Make the chains tight but do not apply
lifting pressure.

when

2 Remove the retaining fasteners from the

center pivot pins.

Note: Do not remove the external snap ring.

3 Using a soft metal drift, remove the center

pivot pins and set aside.

4 Carefully lift and separate the linkage

assembly apart and place it on a structure
capable of supporting it.

26 GS

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August 2022 Service and Repair Manual

Scissor Components

Steer End

1 Platform pivot
2 Number 5 center pivot pin (Qty. 2)
3 Number 5 pivot pin (steer end)
4 Number 4 center pivot pin (Qty. 2)
5 Number 4 inner arm
6 Number 4 pivot pin (steer end)
7 Number 3 center pivot pin (Qty. 2)
8 Lower lift cylinder rod-end pivot pin
9 Number 3 inner arm
10 Number 3 pivot pin (steer end)
11 Number 2 center 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 block (Qty. 2)
17 Number 5 inner arm
18 Number 5 outer arm
19 Number 5 pivot pin (non-steer end)
20 Upper lift cylinder rod-end pivot pin
21 Number 4 outer arm
22 Number 4 pivot pin (non-steer end)
23 Upper lift cylinder barrel-end pivot pin
24 Number 3 outer arm
25 Number 3 pivot pin (non-steer end)
26 Number 2 inner arm
27 Number 2 outer arm
28 Number 2 pivot pin (non-steer end)
29 Lower lift cylinder barrel-end pivot pin
30 Number 1 outer arm

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these
skills and tools could result in
death or serious injury and
significant component damage.
Dealer service is strongly
recommended.

Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly suppor
removed from the machine.

Crushing ha
assembly could become
unbalanced and fall if not
properly supported when
removed from the machine.

Scissor Components

3-3 Scissor Assembly, GS-4069 B E

3-3
Scissor Assembly, GS-4069 BE

How to Disassemble the Scissor
Assembly

4 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
4 inner arm. Make the chains tight but do not
apply lifting pressure.

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

Note: This procedure will require an overhead
supporting device capable of supporting 1000 lbs /
454 kg.

1 Remove the platform. Refer to Repair

Procedure, How to Remove the Platform.

2 Remove the retaining fasteners that attach

the ladder to the drive chassis. Remove the
ladder and set aside.

ted when

5 Remove the retaining fasteners from the

number 5 pivot pins.

Note: Do not remove the external snap ring.

6 Using a soft metal drift, remove the pivot pins

and set aside.

7 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

8 Using a suitable supporting device, attach a

strap to the rod end of the upper lift cylinder.
Do not apply pressure.

9 Remove the upper cylinder rod end pivot pin

retaining fasteners.

10 Using a soft metal drift, remove the pivot pin.

11 Lower the lift cylinder and remove the strap.

12 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
4 inner arm. Make the chains tight but do not
apply lifting pressure.

3 Remove the cables from the linkage

assembly.

28 GS

zard. The linkage

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August 2022 Service and Repair Manual

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow
squirt or spray.

Component damage hazard.
Cables and hoses can be
damaged if they are kinked or
pinched.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supported when
removed from the machine.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supported when
removed from the machine.

Scissor Components

13 Remove the retaining fasteners from the

number 4 pivot pins.

Note: Do not remove the external snap ring.

14 Using a soft metal drift, remove the pivot pins

and set aside.

15 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

16 Tag and disconnect the harness from the

upper lift cylinder valve block.

17 Tag and disconnect the hydraulic hoses from

the upper lift cylinder. Plug the hoses and cap
the fittings.

22 Using a soft metal drift, remove the pivot pin.

23 Lower the lift cylinder and remove the strap.

24 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
3 inner arm. Make the chains tight but do not
apply lifting pressure.

25 Remove the retaining fasteners from the

number 3 pivot pins.

Note: Do not remove the external snap ring.

26 Using a soft metal drift, remove the pivot pins

and set aside.

oil to

18 Remove the cables and hoses from the

linkage assembly.

19 Using a suitable supporting device remove

the retaining fasteners from the upper lift
cylinder. Remove the cylinder.

20 Using a suitable supporting device, 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.

27 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

28 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
2 inner arm. Make the chains tight but do not
apply lifting pressure.

29 Remove the retaining fasteners from the

number 2 pivot pins.

Note: Do not remove the external snap ring.

30 Using a soft metal drift, remove the pivot pins

and set aside.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to
gradually. Do not allow oil to
squirt or spray.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supported when
removed from the machine.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supp
removed from the machine.

Scissor Components

31 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

32 Tag and disconnect the harness from the

lower lift cylinder valve block.

33 Tag and disconnect the hydraulic hoses from

the lower lift cylinder. Plug the hoses and cap
the fittings.

dissipate

34 Remove the hose clamps and hoses from the

number 1 inner arm.

35 Using an overhead supporting device attach a

4 hook sling chain to the ends of the number
1 inner arm. Make the chains tight but do not
apply lifting pressure.

Separate the link sets:

1 Using an overhead supporting device attach a

4 hook sling chain to the ends of the inner
arm. Make the chains tight but do not apply
lifting pressure.

orted when

2 Remove the retaining fasteners from the

center pivot pins.

Note: Do not remove the external snap ring.

3 Using a soft metal drift, remove the center

pivot pins and set aside.

4 Carefully lift and separate the linkage

assembly apart and place it on a structure
capable of supporting it.

36 Remove the two carriage bolts that secure the

inner arm and chassis pivot to the steer end
of the drive chassis.

37 Move the linkage towards the non-steer end

of the machine until the slider feet are clear of
the slider channel.

38 Carefully lift the linkage assembly off of the

machine and place it on a structure capable of
supporting it.

30 GS

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August 2022 Service and Repair Manual

Crushing hazard. The ladder
could fall if not properly
supported when the fasteners
are removed from the machine.

Crushing hazard. The linkage
assembly could become
unbalanced and fall if not
properly supported.

Scissor Components

3-4 Wear Pads

3-4
Wear Pads

2 Remove the fasteners securing the ladder to

the chassis. Remove the ladder from the
machine and set aside.

How to Replace the Scissor Arm
Wear Pad

Platform Scissor Arm Slider Blocks:

1 Remove the platform. Refer to Repair

Procedure, How to Remove the Platform.

2 Remove the slider blocks and discard.

3 Install the slider blocks.

Note: When installing the platform the drill holes in
the slider blocks must be on the top and bottom.

3 Using an overhead lifting device attach a

strap to the #1 inner arm at the non-steer end
of the machine.

Note: The overhead lifting device and strap must
be capable of supporting 5000 lbs / 2268 kg.

4 Install the platform.

Chassis Scissor Arm Wear Pads:

1 Attach a lifting strap from a suitable lifting

device to the ladder at the non-steer end of
the machine. Support the ladder. Do not apply
lifting pressure.

Part No. 1306586GT GS

4 Raise the linkage assembly slightly with the

overhead lifting device just enough to take
pressure off of the slider feet.

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Service and Repair Manual August 2022

Scissor Components

5 Remove the retaining fasteners from the

slider feet pivot pins and set aside.

9 Using a hard rubber mallet, secure the upper

and lower wear pads to the slider feet.

1 Slider foot assembly
2 pivot pin
3 retaining fasteners

6 Using a soft metal drift, remove the pivot pins

and set aside.

7 Remove the slider feet by sliding them out of

the slider channel.

8 Remove the upper and lower wear pads and

discard.

1 upper wear pads
2 slider foot
3 lower wear pad

10 Install the slider feet into the slider channel

and secure them to the linkage assembly with
the pivot pins.

11 Securely tighten the pivot pin retaining

fasteners.

12 Securely install the ladder onto the machine.

Do not over tighten the fasteners.

32 GS

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August 2022 Service and Repair Manual

Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these
skills and tools could result in
death or serious injury and
significant component damage.
Dealer service is strongly
recommended.

Scissor Components

3-5 Lift Cylind ers

3-5
Lift Cylinders

The lift cylinders are single acting hydraulic
cylinders. The GS-2669 and GS-3369 uses one lift
cylinder; the GS-4069 uses two. Each lift cylinder
is equipped with a check valve to prevent
movement in the event of a hydraulic line failure.

How to Remove the Lift Cylinder

GS-2669 BE and GS-3369 BE:

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to 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 scissor assembly. Refer to

Repair Procedure for your model, How to
Disassemble the Scissor Assembly.

GS-2669 BE and GS-3369 BE

1 solenoid valve (proportional lift models)
2 solenoid valve (2 speed lift models)
3 lift cylinder
4 pressure sensor

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Bodily injury hazard. This
procedure requires specific repair
skills, lifting equipment and a
suitable workshop. Attempting
this procedure without these
skills and tools
death or serious injury and
significant component damage.
Dealer service is strongly
recommended.

Scissor Components

GS-4069 BE:

could result in

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to 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 scissor assembly. Refer to

Repair Procedure, How to Disassemble the
Scissor Assembly.

34 GS

GS-4069 BE

1 solenoid valve (proportional lift models)
2 solenoid valve (2 speed lift models)
3 upper lift cylinder
4 lower lift cylinder
5 pressure sensor

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Crushing hazard. Keep hands
clear of the safety arm when
lowering the platform.

Component damage hazard.
The link set cross tube can be
damaged if excessive force is
applied. Do not continue to
lower the platform after the
safety arm makes con
the cross tube.

Scissor Components

3-6 Height An gle Se ns or

3-6
Height Angle Sensor

How to Replace t he Heigh t A ngle S enso r

How to Replace the Height Angle
Sensor

Note: If the angle sensor is replaced, both the
sensor and magnet must be replaced as a set.

1 Start the engine from the ground controls and

raise the platform approximately 18 feet /

5.5 m from the ground.

2 Release the safety arm latch, lift the safety

arm and rotate to a vertical position. Lock the
safety arm in position.

Note: Verify the safety arm is locked in the vertical
position.

3 Lower the platform onto the safety arm. Turn

the machine off.

5 Remove the retaining fasteners securing the

angle sensor mount to the sensor housing.
Remove the sensor assembly and set aside.

1 sensor housing
2 sensor magnet
3 angle sensor
4 angle sensor mount

6 Remove and replace the sensor magnet.

Note: Apply removable thread locker to the
retaining fasteners.

7 Remove and replace the angle sensor

attached to the angle sensor mount.

4 Disconnect the height angle sensor from the

main harness.

Part No. 1306586GT GS

Note: The printed side of the sensor must face

tact with

away from the angle sensor mount.

Note: Apply removable thread locker to the
retaining fasteners.

8 Install the angle sensor assembly onto the

machine. Connect the harness.

9 Raise the platform and rotate the safety arm

to the stowed position.

10 Lower the platform to the stowed position.

11 Calibrate the platform overload system. Refer

to Repair Procedure How to Calibrate the
Platform Overload System.

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Service and Repair Manual August 2022

Burn hazard. Beware of hot
engine components. Contact
with hot engine components
may result in severe

Kohler KD350 Operator's Manual

Genie part number

5885

Kohler KD350 Workshop Manual

Genie part number

1255884

Engines

Engines

4-1 Oil Pressure Switch

4-1
Oil Pressure Switch

The engine oil pressure switch is a normally open
switch. The switch contacts close at approximately
7 psi / 0.48 bar. If the oil pressure drops below the
switch point, the contacts open and the engine will
shut off to prevent damage.

How to Replace the Oil Pressure Switch

1 Open the battery box on the engine side of

the machine.

2 Tag and disconnect the wiring from the

switch. Remove the switch from the engine.

4 Note: Always use pipe thread sealant when

installing a new switch.

burns.

3 Install the new switch and tighten. Torque to

8-18 ft-lbs / 11-24 Nm.

1 oil pressure switch

How to Repair the K ohler K D350 E ngin e

How to Repair the Kohler KD350
Engine

Repair procedures and additional engine
information are available in the Kohler KD350
Operator's Manual (Kohler part number
ED0053028360). Kohler KD350 Workshop Manual
(Kohler part number ED0053029330).

125

36 GS

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August 2022 Service and Repair Manual

Ground Controls

Ground C on t rol s

Ground Controls

The ground controls, used to operate the machine
from the ground, can also be used to tune the
performance of the machine.

The ground controls consist of an Electronic
Control Module (ECM), emergency stop button,
key switch and circuit breaker.

Activating the function enable button and the up or
down at the same time, sends 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 mode, the ground
controls are used to adjust the function speed
parameters, machine models, or machine options.

For further information or assistance, contact
Genie Product Support.

1 machine setup, escape button
2 machine setup, scroll up button
3 LCD display
4 machine setup, scroll down button
5 machine setup, enter button
6 key switch KS1
7 red Emergency Stop P1
8 engine start
9 ECM U1
10 platform down button
11 lift function enable button
12 platform up button

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Ground Controls

5-1 Software R evisi o n L evel

5-1
Software Revision Level

How to Determine the Software
Revision Level

The machine software revision level is displayed at
the ground controls LCD display.

1 Turn the key switch to the ground controls

position. Pull out the red Emergency Stop
button to the on position at both ground and
platform controls.

Result: The display at the platform controls

will show "CH". See example below.

2 Press the ground control scroll down button.

Result: The ground control LCD display will

indicate the software revision and hour meter
information. After 5 seconds, the ground
controls LCD display will display machine
model and hour meter information again.

See example below.

3 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls and turn the key switch to the off
position.

Result: The display at the ground controls will

show the machine model and hour meter
information. See example below.

1 ground control LCD display
2 ground control scroll down button

38 GS

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August 2022 Service and Repair Manual

Tip
function speeds higher than
specified in this procedure.
Setting the function speeds
greater than specifications could
cause the machine to tip over
resulting in death or
injury.

Tip
must only be performed by a
trained service professional.
Attempting this procedure
without the necessary skills
could result in death or serious
injury.

Ground Controls

5-2 Machine Set up

5-2
Machine Setup

How to Setup the Machine from
Ground Controls

The ground controls can be used to setup the
machine parameters from the ground. Features
that can be adjusted from the ground controls
include machine Model, Options and Speed setup.
This menu can only be entered from ground
controls with the key switch in the ground controls
position.

-over hazard. Do not adjust

serious

-over hazard. This procedure

2 Press and hold the ground control scroll up

and scroll down buttons.

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll up 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:

Note: Select a test area that is firm, level and free
of obstructions.

1 Turn the key switch to the ground controls

position and pull out the red Emergency Stop
button to the on position at the platform
controls.

Part No. 1306586GT GS

4 Use the ground control menu buttons to select

machine Model, Options and Speed Setup
parameters. Follow the menu structure
indicated on the ground control LCD display.

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Service and Repair Manual August 2022

Tip-over hazard. Failure to install
or calibrate the level sensor as
instructed will compromise
machine stability and
machine to tip over, resulting in
death or serious injury. Do not
install or calibrate the level
sensor other than specified in
this procedure.

Ground Controls

5-3 Auxiliary P latf or m Low eri n g

5-3
Auxiliary Platform Lowering

In the event of a main power failure, activating the
auxiliary enable and auxiliary platform lowering
toggle switches at the ground controls will lower
the platform. There is no adjustment required.

5-4 Level Sens or - Mod els witho ut O utrigger s

5-4
Level Sensor - Models without
Outriggers

The Electronic Control Module (ECM) is
programmed to deactivate the lift and drive
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 and Calibrate the
Level Sensor

cause the

Note: Perform this procedure with the machine on
a firm, level surface and the platform in the stowed
position. Use a digital level to confirm.

1 auxiliary enable toggle switch
2 auxiliary lowering toggle switch

1 Remove the platform controls from the

platform.

Note: If you are not installing a new level
sensor, or you have installed an outrigger level
sensor, proceed to step 7.

40 GS

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Tip
sensor must be installed with the
"X" on the level sensor base
t
machine. Failure to install the tilt
level sensor as instructed could
result in the machine tipping
over causing death or serious
injury.

Ground Controls

2 Locate the level sensor in the ground controls

compartment.

1 ground control box
2 level sensor

3 Tag and disconnect the level sensor wire

harness from the chassis wire harness.

4 Remove the level sensor retaining fasteners

and remove the level sensor from the
machine.

5 Install the new level sensor onto the machine

with the "X" on the level sensor base towards
the steer end of the machine. Install and
tighten the level sensor retaining fasteners.

-over hazard. The tilt level

owards the steer end of the

1 "Y" indicator
2 level sensor
3 "X" indicator
4 chassis

6 Connect the wire harness to the level sensor.

7 Adjust the level sensor retaining fasteners

until the bubble in the top of the level sensor
is centered in the circles.

Note: Be sure there are threads showing through
the top of the adjusting fasteners.

8 Turn the key switch to ground control and pull

out the red Emergency Stop button to the on
position at both ground and platform controls.

Result: The tilt sensor alarm should not

sound.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Ground Controls

9 Center a lifting jack under the drive chassis at

the ground controls side of the machine.

10 Raise the machine approximately 4 inches /

10 cm.

21 Place a 2.25 x 10 x 10 inch / 5.72 x 25 x

25 cm thick steel block under both wheels at
the ground controls side of the machine.

22 Lower the machine onto the blocks.

11 Place a 1.94 x 10 x 10 inch / 4.93 x 25 x

25 cm thick steel block under both wheels at
the ground controls side of the machine.

12 Lower the machine onto the blocks.

13 Raise the platform approximately 12 feet /

3,6 m.

Result: The tilt alarm does not sound and all

functions will operate. Proceed to step 15.

Result: The drive function and the lift function

will not operate and the tilt alarm will sound at
180 beeps per minute. Proceed to step 14.

14 Turn the level sensor adjusting nuts just until

the level sensor alarm does not sound.

15 Lower the platform to the stowed position.

16 Raise the machine approximately 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.

23 Raise the platform approximately 12 feet /

3,6 m.

Result: The drive function and the lift function

will not operate and the tilt alarm will sound at
180 beeps per minute.

Result: If the tilt sensor alarm does not sound,

adjust the tilt level sensor until the alarm just
begins to sound.

24 Lower the platform to the stowed position.

25 Push in the red Emergency Stop button to the

off position at both the ground and platform
controls.

26 Turn the key switch to the off position.

27 Raise the machine approximately 4 inches /

10 cm.

28 Remove the blocks from under both wheels.

29 Lower the machine and remove the jack.

20 Raise the machine approximately 4 inches /

10 cm.

™

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Tip-over hazard. Failure to install
or calibrate the level sensor as
instructed will compromise
machine stability and cause the
machine to tip over, resulting in
death or serious injury. Do not
install or calibrate the level
sensor other
this procedure.

Ground Controls

5-5 Level Sens or - Mod els w ith Outri ggers

5-5
Level Sensor - Models with
Outriggers

The Electronic Control Module (ECM) is
programmed to deactivate the lift and drive
functions and activate an alarm when a signal is
received from the level sensor.

When the outriggers are stowed, the tilt alarm
sounds when the incline of the chassis exceeds 2°
to the side.

When the outriggers are deployed, functions will
be disabled and and fault will be displayed when
the incline of the chassis exceeds 0.8° to the side.

At all times, the tilt alarm sounds when the incline
of the chassis exceeds 3° to the front or rear.

3 Tag and disconnect the wire harness from the

level sensor.

How to Install the Outrigger Level
Sensor

than specified in

Note: Perform this procedure with the machine on
a firm, level surface that is free of obstructions.

1 Turn the key switch to the off position and

push in the red Emergency Stop button to the
off position at both the ground and platform
controls.

2 Locate the level sensor in the ground controls

compartment.

1 ground control box
2 level sensor

4 Remove the level sensor retaining fasteners

and remove the level sensor from the
machine.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Tip
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
result in the machine tipping
over causing death or serious
injury.

Ground Controls

5 Install the new level sensor onto the machine

with the "X" on the level sensor base towards
the steer end of the machine. Install and
tighten the level sensor retaining fasteners.

-over hazard. The tilt level

6 Connect the wire harness to the level sensor.

7 Adjust the level sensor retaining fasteners

until the bubble in the top of the level sensor
is centered in the circles.

Note: Be sure there are threads showing through
the top of the adjusting fasteners.

8 Calibrate the new level sensor. Refer to

Repair Procedure, How to Install and
Calibrate the Level Sensor.

1 chassis
2 level sensor
3 "Y" indicator
4 "X" indicator

44 GS

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August 2022 Service and Repair Manual

Tip
machine on a surface that is not
level while in Service Override
mode will result in death or
serio
operating procedures and safety
precautions. Do not use Service
Override mode if you are not
trained and familiar with the
operation of the machine.

Ground Controls

5-6 Service O ver ride Mod e

5-6
Service Override Mode

The Electronic Control Module (ECM) is
programmed with a Service Override mode.
Service Override mode is only indented for certain
circumstances and is not part of the normal
machine operation. Service Override mode should
only be accessed by trained personal to repair
faults and/ or a malfunctioning machine.

Note: Service Override mode can only be entered
at the ground controls and is intended to allow the
platform to be raised or lowered. Once the
platform has reached the maximum allowable
height, the system will exit Service Override mode.
Repeat this procedure to lower the platform.

Note: When in Service Override mode, an audible
alarm will sound.

Note: Before entering Service Override mode, fault
codes or the malfunction affecting 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
leveled or fully retracted.

1 Turn the key switch to the ground controls

position and pull out the red Emergency Stop
button to the on position at the platform
controls.

2 Press and hold the ground control scroll up

and scroll down buttons.

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

3 Pull out the red Emergency Stop button to the

on position at the ground controls.

Part No. 1306586GT GS

-over hazard. Operating the

us injury. Follow proper

™

-2669 BE • GS™-3369 BE • GS™-4069 BE 45

Result: The ground controls LCD display will

show the following:

4 Release the Scroll Up and Scroll Down

buttons after the ground controller powers up.

Service and Repair Manual August 2022

Ground Controls

5 At 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 display will

show the following:

7 Press the enter button.

Result: The ground controls LCD display will

show the following:

46 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Component damage hazard.
After replacing the hydraulic
pump, it is critical to return the
lift and drive speed settings to
original factory specif
Refer to Specifications,

Performance Specifications

Hydraulic Pump

Hydraulic Pum p

6-1 Hydraulic Pum p

6-1
Hydraulic Pump

The hydraulic pump is a single section, gear-type
pump.

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

How to Test the Hydraul ic P um p

How to Test the Hydraulic Pump

1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to test port #1 (TP1) on the
function manifold.

2 Remove the platform controls 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 gauge. Refer to Specifications,
Hydraulic Specifications.

How to Remov e th e Hy d raulic P u mp

How to Remove the Hydraulic
Pump

1 Tag, disconnect and plug the hydraulic hoses

on the pump. Cap the fittings on the pump.

2 Remove the pump mounting bolts. Carefully

remove the pump.

ications.

.

Part No. 1306586GT GS

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-2669 BE • GS™-3369 BE • GS™-4069 BE 47

Service and Repair Manual August 2022

Hydraulic Pump

How to Cali brat e th e Hyd rauli c P ump

How to Calibrate the Hydraulic
Pump

1 Turn the key switch to the ground controls

position and pull out the red Emergency Stop
button to the on position at the platform
controls.

2 Press and hold the ground control scroll up

and scroll down buttons.

4 Release the Scroll Up and Scroll Down

buttons after the ground controller powers up.

5 At the ground controls, use the Scroll Up or

Scroll Down buttons to scroll to Select Option.

6 Press the Enter button.

7 Use the Scroll Up or Scroll Down buttons to

scroll to Select Option Pump Efficiency.

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll 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:

8 Press the Enter button.

Result: The ground controls LCD display will

show the following:

9 Press the Scroll Down button.

Result: The ground controls LCD display will

show the following:

48 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Hydraulic Pump

10 Press the Enter button.

Result: The ground controls LCD display will

show the following:

11 Press and Hold the Enter button.

Result: The ground controls LCD display will

scroll through the following screens.

Note: Continue to hold the Enter button 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
range.

Note: The screen will return to the options screen
after 2 seconds.

Result: The ground controls LCD displays the

following screen. Calibration data is not within
range. The pump needs to be repaired or
replaced.

12 For a bad result, press the Enter button to

return to the option screen

13 Push in the red Emergency Stop button to the

off position.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

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50 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Index
No.

Description

Function Torque

1 Check valve

Oscillate circuit

lbs / 27 Nm

2 Solenoid Valve,

Oscillate / Accumulator

lbs / 27 Nm

Orifice

3
(GS 2669
(GS 3369
(GS 4069

Lift circuit

lbs / 27 Nm

4 Accumulator

Oscillate circuit

lbs / 15 Nm

5 Solenoid Valve,

Oscillate circuit

lbs / 27 Nm

6 Flow control valve,

Controls flow to the oscillate
circuit

lbs / 27 Nm

7 Relief valve, 350

System relief

lbs / 27 Nm

8 Relief valve, 150

Steer circuit

lbs / 27 Nm

9 Check valve

Load sense

19

Nm

10 Flow control valve,

Controls flow to the steer circuit

lbs / 27 Nm

11

Solenoid valve, 3 position 5 way

FL

Steer circuit

lbs / 27 Nm

Check valve

12 Pressure switch

Oscillate / Accumulator

lbs / 15 Nm

13 Solenoid Valve,

Lift circuit

lbs / 34 Nm

14 Solenoid Valve,

Oscillate right

lbs / 27 Nm

15

Relief valve, 3300 psi / 228 bar

FQ

Oscillate relief

lbs / 27 Nm

16 Solenoid Valve,

Oscillate left

lbs / 27 Nm

Manifolds

Manifol ds

7-1 Function Manifold C ompone nts

7-1
Function Manifold Components

The function manifold is located inside the hydraulic compartment.

FA

2 position 3 way FB

FC

Relief valve

- 3100 psi / 214 bar)

- 2900 psi / 200 bar)

- 2850 psi / 197 bar)

FE

2 position 3 way FF

1 gpm / 3.8 L/min FG

0 psi / 241 bar FH

0 psi / 103 bar FI

FJ

2 gpm / 7.6 L/min FK

FM

FN

2 position 3 way FO

2 position 3 way FP

2 position 3 way FR

Schematic

Item

FD

20 ft-

20 ft-

20 ft-

11 ft-

20 ft-

20 ft-

20 ft-

20 ft-

12-14 ft-lbs / 16-

20 ft-

20 ft-

11 ft-

25 ft-

20 ft-

20 ft-

20 ft-

Part No. 1306586GT GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE 51

Service and Repair Manual August 2022

Manifolds

7-1a Function Ma nifold C ompon ents - M odels w i th P ro por tion al R elief (fr om s eri al nu mbe r GS69 16 F-1 0015 )

52 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Index
No.

Description

Function Torque

1

Relief valve

FQ

Oscillate relief

lbs / 27 Nm

2 Accumulator

Oscillate circuit

lbs / 15 Nm

3
(GS 2669
(GS 3369
(GS 4069 - 2850 psi / 197 bar)

Lift circuit

lbs / 27 Nm

4 Check valve

Oscillate circuit

lbs / 27 Nm

5

Proportional relief valve

FH

System relief

lbs / Nm

100

6 Relief valve, 150

Steer circuit

20 ft-lbs / 27 Nm

7 Check valve

Load sense

20 ft-lbs / 27 Nm

8 Flow control valve

Controls flow to the steer circuit

lbs / 27 Nm

9 Solenoid valve,

Steer circuit

lbs / 27 Nm

Check valve

10 Flow control valve,

Controls flow to the oscillate
circuit

lbs / 27 Nm

11 Solenoid Valve,

Oscillate circuit

lbs / 27 Nm

12

Pressure switch

FN

Oscillate / Accumulator

lbs / 15 Nm

13 Solenoid Valve,

Oscillate / Accumulator

lbs / 27 Nm

Orifice

Oscillate / Accumulator

14 Solenoid Valve,

Oscillate right

lbs / 27 Nm

15

Solenoid Valve, 2 position 3 way

FO

Lift circuit

lbs / 27 Nm

16

Solenoid Valve, 2 position 3 way

FR

Oscillate left

lbs / 27 Nm

Manifolds

7-1
Function Manifold Components Models with Proportional Relief (from
serial number GS6916F-10015)

The function manifold is located inside the hydraulic compartment.

FE

Relief valve

- 3100 psi / 214 bar)

- 2900 psi / 200 bar)

FA

- 3500 psi / 7 - 241 bar

0 psi / 103 bar FI

FJ

2 gpm / 7.6 L/min FK

3 position 5 way FL

FM

1 gpm / 3.8 L/min FG

2 position 3 way FF

2 position 3 way FB

FC

Schematic

Item

FD

20 ft-

11 ft-

20 ft-

20 ft-

25 ft-

20 ft-

20 ft-

20 ft-

20 ft-

11 ft-

20 ft-

Part No. 1306586GT GS

2 position 3 way FP

™

-2669 BE • GS™-3369 BE • GS™-4069 BE 53

20 ft-

20 ft-

20 ft-

Service and Repair Manual August 2022

Manifolds

54 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Tip
the relief valve higher than
specified.

Manifolds

7-2 Valve Adjust ments - Fu nct ion Ma nifol d

7-2
Valve Adjustments - Function
Manifold

How to Adjust the System Relief Valve

How to Adjust the System Relief
Valve

Note: Perform this procedure with the machine in
the stowed position.

Note: Refer to Function Manifold Component list to
locate the system relief valve.

1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to test port #1 (TP1) on the
function manifold.

2 Remove the platform controls from the

platform and place the controls near the
function manifold on the hydraulic tank side of
the machine.

7 Adjust the internal hex socket. Turn it

clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.

-over hazard. Do not adjust

8 Repeat this procedure beginning with step

4 to confirm the relief valve pressure.

9 Remove the pressure gauge.

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 out the red Emergency Stop button to the
on position at both the ground and platform
controls.

5 Press and hold the enable and platform up

buttons OR select the platform function button
and activate platform up. Note the pressure
reading on the pressure gauge. Refer to
Specifications, Hydraulic Components
Specifications.

6 Use a wrench to hold the system relief valve

and remove the cap.

1 test port #1
2 system relief valve
3 platform up valve

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Manifolds

How to Adjust the System Relief
Valve – Models with Proportional
Relief

Note: Perform this procedure with the machine in
the stowed position.

Note: Refer to Function Manifold Component list to
locate the system relief valve.

1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to test port #1 (TP1) on the
function manifold.

2 Remove the platform controls from the

platform and place the controls near the
function 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.

Result: If the pressure reading is not within

range, replace the valve.

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
controls.

5 Press and hold the enable and platform up

buttons OR select the platform function button
and activate platform up. Note the pressure
reading on the pressure gauge. Refer to
Specifications, Hydraulic Components
Specifications.

1 test port #1
2 proportional relief valve
3 platform up valve
4

56 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Tip
the relief valve higher than
specified.

Manifolds

How to Adjust the Oscillate Relief Valve

How to Adjust the Oscillate Relief
Valve

Note: Perform this procedure with the machine in
the stowed position and in high torque mode.

1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to test port #2 (TP2) on the
function manifold.

2 Disconnect the harness from the oscillate

supply coil and the steer right coil.

3 Connect the oscillate supply harness to the

steer right coil and the steer right harness to
the oscillate supply 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
controls.

10 Remove the pressure gauge.

5 Steer the machine to the right and hold. Note

the pressure readings on the pressure gauge.
Refer to Specifications, Hydraulic
Components Specifications.

6 Use a wrench to hold the oscillate relief valve

and remove the cap.

7 Adjust the internal hex socket. Turn it

clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.

-over hazard. Do not adjust

8 Repeat this procedure beginning with step

5 to confirm the relief valve pressure.

9 Connect the harness back to the original

position.

1 test port #2
2 oscillate supply coil
3 steer right coil
4 oscillate relief valve

Part No. 1306586GT GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE 57

Service and Repair Manual August 2022

Tip
the relief valve higher than
specif

Manifolds

How to Adjust the Oscillate Relief
Valve - Models with Proportional
Relief

Note: Perform this procedure with the machine in
the stowed position and in high torque mode.

1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to test port #2 (TP2) on the
function manifold.

2 Disconnect the harness from the oscillate

supply coil and the steer right coil.

3 Connect the oscillate supply harness to the

steer right coil and the steer right harness to
the oscillate supply coil.

4 Disconnect the harness from the proportional

relief valve.

5 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
controls.

11 Remove the pressure gauge.

6 Steer the machine to the right and hold. Note

the pressure readings on the pressure gauge.
Refer to Specifications, Hydraulic
Components Specifications.

7 Use a wrench to hold the oscillate relief valve

and remove the cap.

8 Adjust the internal hex socket. Turn it

clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.

-over hazard. Do not adjust

ied.

9 Repeat this procedure beginning with step

5 to confirm the relief valve pressure.

10 Connect the harness back to the original

position.

1 test port #2
2 oscillate supply coil
3 steer right coil
4 oscillate relief valve
5 proportional relief valve

58 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Tip
the relief valve higher than
specified.

Manifolds

How to Adjus t th e St ee r Relie f Valv e

How to Adjust the Steer Relief
Valve

Note: Perform this procedure with the machine in
the stowed position.

1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to test port #1 (TP1) on the
function manifold.

2 Remove the platform controls from the

platform and place the controls near the
function manifold on the hydraulic tank side of
the machine.

3 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
controls.

4 Steer the machine fully to the right or left and

hold. Note the pressure reading on the
pressure gauge. Refer to Specifications,
Hydraulic Components Specifications.

8 Remove the pressure gauge.

5 Use a wrench to hold the steer relief valve

and remove the cap.

6 Adjust the internal hex socket. Turn it

clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.

-over hazard. Do not adjust

7 Repeat this procedure beginning with step

4 to confirm the relief valve pressure.

1 test port #1
2 steer relief valve

Part No. 1306586GT GS

™

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Service and Repair Manual August 2022

Tip
the relief valve higher than
specified.

Manifolds

How to Adjust the Steer Relief
Valve - Models with Proportional
Relief

Note: Perform this procedure with the machine in
the stowed position.

1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to test port #1 (TP1) on the
function manifold.

2 Disconnect the harness from the proportional

relief valve.

3 Remove the platform controls from the

platform and place the controls near the
function manifold on the hydraulic tank side of
the machine.

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
controls.

10 Remove the pressure gauge.

5 Steer the machine fully to the right or left and

hold. Note the pressure reading on the
pressure gauge. Refer to Specifications,
Hydraulic Components Specifications.

6 Use a wrench to hold the steer relief valve

and remove the cap.

7 Adjust the internal hex socket. Turn it

clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.

-over hazard. Do not adjust

8 Repeat this procedure beginning with step

4 to confirm the relief valve pressure.

9 Connect the harness to the proportional relief

valve.

1 test port #1
2 steer relief valve
3 proportional relief valve

60 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Manifolds

How to Adjus t th e Pl atfo rm U p Rel ie f V alve - M odels w i th P latf or m Ove rl oa d

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

Note: Verify the hydraulic oil level is within the top
2 inches / 5 cm of the sight gauge.

1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to test port #1 (TP1) on the
function manifold.

3 Press and hold the ground control scroll up

and scroll down buttons.

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll down button
4 escape button
5 LCD display

4 Pull out the red Emergency Stop button to the

on position at the ground controls.

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
controls.

Result: The ground controls LCD display will

show the following:

5 Release the Scroll Up and Scroll Down

buttons after the ground controller powers up.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Manifolds

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 display will

show the following:

8 Press 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 will return to
SELECT OPTION, PLAT. OVERLOAD.

10 Press the Scroll Down button to scroll to

Down Delay.

Result: The ground controls LCD display will

show the following:

11 Press the enter button.

Result: The ground controls LCD display will

show the following:

62 GS

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Manifolds

12 Press the enter button.

Result: The ground controls LCD display will

show the following:

Note: After 1 second the display will return to
SELECT OPTION, DOWN DELAY.

13 Push in the red Emergency Stop button to the

off position.

14 Pull out the red Emergency Stop button to the

on position and raise the platform
approximately 10 feet / 3 m.

15 Lift the safety arm, move it to the center of the

scissor arm and rotate down to a vertical
position.

16 Lower the platform onto the safety arm.

17 Push in the red Emergency Stop button to the

off position.

18 Locate and disconnect the lift cylinder

pressure sensor harness.

1 solenoid valve (proportional lift models)
2 solenoid valve (2 speed lift models)
3 lift cylinder
4 pressure sensor

19 Pull out the red Emergency Stop button to the

on position and raise the platform
approximately 10 feet / 3 m.

20 Return the safety arm to the stowed position.

21 Lower the platform to the stowed position.

Part No. 1306586GT GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE 63

Service and Repair Manual August 2022

GS-2669

g

GS-3369

g

GS-4069

g

Tip
adjust the relief valves to
specification could result in the
machine tipping over, causing
death or serious injury. Do not
adjust the
higher than specifications.

Manifolds

22 Using a suitable lifting device, place and

secure the maximum rated load in the center
of the platform deck.

30 Lift the safety arm, move it to the center of the

scissor arm and rotate down to a vertical
position.

680 k

454 k

363 k

23 Press and hold the 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 the
pressure. Refer to Specifications, Hydraulic
Component Specifications.

24 Hold the lift relief valve (item 1) with a wrench

and remove the cap.

25 Adjust the internal hex socket. Turn it

clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.

-over hazard. Failure to

relief valve pressures

31 Lower the platform onto the safety arm.

32 Push in the red Emergency Stop button to the

off position.

33 Connect the harness to the lift cylinder

pressure sensor.

34 Pull out the red Emergency Stop button to the

on position and raise the platform
approximately 10 feet / 3 m.

35 Return the safety arm to the stowed position.

36 Lower the platform to the stowed position.

37 Push in the red Emergency Stop button to the

off position.

38 Press and hold the ground control scroll up

and scroll down buttons.

39 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:

26 Repeat this procedure beginning with step

22 to confirm the relief valve pressure.

27 Lower the platform to the stowed position.

28 Remove the weight from the platform.

29 Raise the platform approximately 10 feet /

3 m.

64 GS

40 Release the Scroll Up and Scroll Down

buttons after the ground controller powers up.

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Manifolds

41 At the ground controls, use the Scroll Down

button to scroll to SELECT OPTION.

Result: The ground controls LCD display will

show the following:

42 Press the enter button.

Result: The ground controls LCD display will

show the following:

43 Press the enter button.

Result: The ground controls LCD display will

show the following:

44 Press the enter button.

Result: The ground controls LCD display will

show the following:

Note: After 1 second the display will return to
SELECT OPTION, PLAT. OVERLOAD.

45 Press the Scroll Down button to scroll to

Down Delay.

Result: The ground controls LCD display will

show the following:

46 Press the enter button.

Result: The ground controls LCD display will

show the following:

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Manifolds

47 Press the enter button.

Result: The ground controls LCD display will

show the following:

Note: After 1 second the display will return to
SELECT OPTION, DOWN DELAY.

48 Push in the red Emergency Stop button to the

off position.

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

Note: Verify the hydraulic oil level is within the top
2 inches / 5 cm of the sight gauge.

1 Connect a 0 to 5000 psi / 0 to 350 bar

pressure gauge to test port #1 (TP1) on the
function manifold.

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
controls.

3 Press and hold the ground control scroll up

and scroll down buttons.

49 Perform Maintenance Procedures, Test the

Platform overload System and Down Limit
Switch Decent delay.

Ground Control Menu Buttons

1 scroll down button
2 enter button
3 scroll up button
4 escape button
5 LCD display

66 GS

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August 2022 Service and Repair Manual

Manifolds

4 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:

5 Release the Scroll Up and Scroll Down

buttons after the ground controller powers up.

6 At the ground controls, use the Scroll Down

button to scroll to SELECT OPTION.

9 Press the enter button.

Result: The ground controls LCD display will

show the following:

Note: After 1 second the display will return to
SELECT OPTION, PLAT. OVERLOAD.

Result: The ground controls LCD display will

show the following:

7 Press the enter button.

Result: The ground controls LCD display will

show the following:

8 Press the enter button.

Result: The ground controls LCD display will

show the following:

10 Press the Scroll Down button to scroll to

Down Delay.

Result: The ground controls LCD display will

show the following:

11 Press the enter button.

Result: The ground controls LCD display will

show the following:

Part No. 1306586GT GS

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Service and Repair Manual August 2022

GS

g

GS

g

GS

g

Manifolds

12 Press the enter button.

Result: The ground controls LCD display will

show the following:

Note: After 1 second the display will return to
SELECT OPTION, DOWN DELAY.

13 Push in the red Emergency Stop button to the

off position.

14 Pull out the red Emergency Stop button to the

on position and raise the platform
approximately 10 feet / 3 m.

15 Lift the safety arm, move it to the center of the

scissor arm and rotate down to a vertical
position.

16 Lower the platform onto the safety arm.

17 Push in the red Emergency Stop button to the

off position.

18 Locate and disconnect the lift cylinder

pressure sensor harness.

1 solenoid valve (proportional lift models)
2 solenoid valve (2 speed lift models)
3 lift cylinder
4 pressure sensor

19 Pull out the red Emergency Stop button to the

on position and raise the platform
approximately 10 feet / 3 m.

20 Return the safety arm to the stowed position.

21 Lower the platform to the stowed position.

22 Using a suitable lifting device, place and

secure the maximum rated load in the center
of the platform deck.

68 GS

-2669 680 k

-3369 454 k

-4069 363 k

23 Press and hold the 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 the
pressure. Refer to Specifications, Hydraulic
Component Specifications.

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August 2022 Service and Repair Manual

Tip
adjust the relief valves to
specification could result in the
machine tipping over, causing
death or serious injury. Do not
adjust the relief valve pressures
higher than specifications.

Manifolds

24 Hold the lift relief valve (item 1) with a wrench

and remove the cap.

37 Press and hold the ground control scroll up

and scroll down buttons.

25 Adjust the internal hex socket. Turn it

clockwise to increase the pressure or
counterclockwise to decrease the pressure.
Install the relief valve cap.

-over hazard. Failure to

Repeat this procedure beginning with step 22 to
confirm the relief valve pressure.

26 Lower the platform to the stowed position.

27 Remove the weight from the platform.

28 Raise the platform approximately 10 feet /

3 m.

29 Lift the safety arm, move it to the center of the

scissor arm and rotate down to a vertical
position.

30 Lower the platform onto the safety arm.

31 Push in the red Emergency Stop button to the

off position.

38 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:

39 Release the Scroll Up and Scroll Down

buttons after the ground controller powers up.

40 At the ground controls, use the Scroll Down

button to scroll to SELECT OPTION.

Result: The ground controls LCD display will

show the following:

41 Press the enter button.

Result: The ground controls LCD display will

show the following:

32 Connect the harness to the lift cylinder

pressure sensor.

33 Pull out the red Emergency Stop button to the

on position and raise the platform
approximately 10 feet / 3 m.

34 Return the safety arm to the stowed position.

35 Lower the platform to the stowed position.

36 Push in the red Emergency Stop button to the

off position.

Part No. 1306586GT GS

42 Press the enter button.

Result: The ground controls LCD display will

show the following:

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Service and Repair Manual August 2022

Manifolds

43 Press the enter button.

46 Press the enter button.

Result: The ground controls LCD display will

show the following:

Note: After 1 second the display will return to
SELECT OPTION, PLAT. OVERLOAD.

44 Press the Scroll Down button to scroll to

Down Delay.

Result: The ground controls LCD display will show
the following:

Result: The ground controls LCD display will show

the following:

Result: The ground controls LCD display will

show the following:

Note: After 1 second the display will return to
SELECT OPTION, DOWN DELAY.

47 Push in the red Emergency Stop button to the

off position.

48 Perform Maintenance Procedures, Test the

Platform overload System and Down Limit
Switch Decent delay.

45 Press the enter button.

Result: The ground controls LCD display will show
the following:

™

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August 2022 Service and Repair Manual

Index
No.

Description

Function Torque

1

Solenoid valve, 3 position 4 way

BA

Outriggers extend / retract

lbs / 54 Nm

Manifolds

7-3 Outrigge r Mani fold C ompon ent s

7-3
Outrigger Manifold Components

The outrigger manifold is located inside the hydraulic compartment.

Schematic

Item

40 ft-

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove a
watches and other jewelry.

Description

Specification

Solenoid valve, 3 position 5 way

Manifolds

7-4 Valve Coils

7-4
Valve Coils

How to Test a Coil

A properly functioning coil provides an
electromagnetic force which operates the solenoid
valve. Critical to normal operation is continuity
within the coil. Zero resistance or infinite
resistance indicates the coil has failed.

Valve Coil Resistance
Specification

Note: The following coil resistance specifications
are at an ambient temperature of 68°F / 20°C. As
valve coil resistance is sensitive to changes in air
temperature, the coil resistance will typically
increase or decrease by 4% for each 18°F / 20°C
that your air temperature increases or decreases
from 68°F / 20°C.

Since coil resistance is sensitive to temperature,
resistance values outside specification can
produce erratic operation. When coil resistance
decreases below specification, amperage
increases. As resistance rises above specification,
voltage increases.

While valves may operate when coil resistance is
outside specification, maintaining coils within
specification will help ensure proper valve function
over a wide range of operating temperatures.

ll rings,

Note: If the machine has been in operation, allow
the coil to cool at least 3 hours before performing
this test.

1 Tag and disconnect the wiring from the coil to

be tested.

2 Test the coil resistance using a multimeter set

to resistance (Ω). Refer to the Valve Coil
Resistance Specification table.

Solenoid valve, 2 position 2 way
24V DC with diode
(schematic items CA, CB, CC, CD,
CE, CF)

Solenoid valve, 2 position 3 way
24V DC with diode
(schematic items BA, FB, FF, FO, FP,
FR, )

24V DC with diode (schematic item
FL)

25Ω

35Ω

35Ω

Result: If the resistance is not within the

adjusted specification, plus or minus 10%,
replace the coil.

72 GS

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August 2022 Service and Repair Manual

Electrocution/burn hazard.
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

Resistor 10

Genie part number 27287

Manifolds

How to Test a Coil Diode

Properly functioning coil diodes protect the
electrical circuit by suppressing voltage spikes.
Voltage spikes naturally occur within a function
circuit following the interruption of electrical current
to a coil. Faulty diodes can fail to protect the
electrical system, resulting in a tripped circuit
breaker or component damage.

1 Test the coil for resistance. Refer to Repair

Procedure, How to Test a Coil.

2 Connect a 10W resistor to the negative

terminal of a known good 9V DC battery.
Connect the other end of the resistor to a
terminal on the coil.

Ω

Note: The battery should read 9V DC or more
when measured across the terminals.

1 multimeter
2 9v DC battery
3 10Ω resistor
4 coil

Note: Dotted lines in illustration indicate a reversed
connection as specified in step 6.

3 Set a multimeter to read DC current.

Note: The multimeter, when set to read DC
current, should be capable of reading up to
800 mA.

Part No. 1306586GT GS

4 Connect the negative lead to the other

terminal on the coil.

5 Momentarily connect the positive lead from

the multimeter to the positive terminal on the
9V DC battery. Note and record the current
reading.

6 At the battery or coil terminals, reverse the

connections. Note and record the current
reading.

Result: Both current readings are greater than

0 mA and are different by a minimum of 20%.
The coil is good.

Result: If one or both of the current readings

are 0 mA, or if the two current readings do not
differ by a minimum of 20%, the coil and/or its
internal diode are faulty and the coil should be
replaced.

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Service and Repair Manual August 2022

Explosion and fire hazard.
Engine fuels are combustible.
Perform this procedure in an
open, well
from heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.

Explosion and fire hazard. When
transferring fuel, connect a
grounding wire between the
machine and pump or container.

Explosion and fire hazard. Never
drain or store fuel in an open
container due to the possibility of
fire.

Fuel and Hydraulic Tanks

Fuel and H ydra ul ic Ta nks

8-1 Fuel Tank

8-1
Fuel Tank

How to Remove the Fuel Tank

-ventilated area away

6 Remove the cooling fan and fan shroud and

set aside.

7 Remove the fuel tank cover above the fuel

tank.

8 Disconnect the return line from the top of the

fuel tank.

9 Disconnect and plug the supply line from the

bottom of the tank.

10 Remove the fuel tank from the machine.

Note: Clean the fuel tank and inspect for cracks or
other damage before installing.

1 Remove the fuel filler cap from the tank.

2 Using an approved hand-operated pump,

drain the fuel tank into a suitable container.
Refer to Specifications, Machine
Specifications.

Note: Be sure to only use a hand operated pump
suitable for use with gasoline and/or diesel fuel.

3 Clean up any fuel that may have spilled.

4 Remove the intake grill located below the fuel

tank and set aside.

5 Disconnect the engine harness from the

cooling fan inside the engine compartment.

74 GS

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August 2022 Service and Repair Manual

Component damage hazard. The
work area and surfaces where
this procedure will be performed
must be clean and free of debris
that could get into the hydraulic
system and cause severe
component damage. Dealer
service is recommende

Bodily injury hazard. Spraying
hydraulic oil
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Component damage hazard.
During installation, do not
overtighten the hydraulic tank
strap mounting fastener.

Fuel and Hydraulic Tanks

8-2 Hydraulic Tank

8-2
Hydraulic Tank

The primary functions of the hydraulic tank is to
cool, clean and deaerate the hydraulic fluid during
operation. It utilizes internal suction strainer for the
pump supply line.

3 Tag and disconnect the harnesses from the

ground control box.

4 Remove the ground control box from the

machine and set aside.

5 Tag, disconnect and plug the hydraulic hoses

from the hydraulic tank. Cap the fittings on the
tank.

How to Remove the Hydraulic
Tank

d.

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic 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 Specifications,
Machine Specifications.

6 Loosen the hydraulic tank mounting strap

fastener. Pull the tank strap to the side.

Note: Do not remove the tank strap.

7 Remove the hydraulic tank from the machine.

Note: Clean the hydraulic tank and inspect for
cracks or other damage before installing.

Part No. 1306586GT GS

can penetrate and

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Service and Repair Manual August 2022

Crushing hazard. The chassis
will fall if not properly supported.

Steer Axle Components

Steer Axle Components

9-1 Yoke Asse mbly

9-1
Yoke Assembly

How to Remove the Yoke
Assembly

1 Chock both sides of the wheels at the non-

steer end of the machine.

2 Center a lifting jack under the drive chassis at

the steer end of the machine.

3 Loosen the wheel lug nuts. Do not remove

them.

4 Raise the machine approximately 2 inches /

5 cm. Place blocks under the chassis for
support.

5 Remove the wheel lug bolts. Remove the tire

and wheel assembly.

6 Support and secure the yoke and assembly

with a lifting device.

Left side yoke:

7 Remove the retaining fasteners from the tie

rod pivot pin.

1 upper king pin
2 tie rod pivot pin
3 lower king pin
4 steer sensor assembly
5 yoke assembly

8 Use a small pry bar to move the pivot pin

down enough to clear the steer sensor
assembly.

76 GS

9 Remove the steer sensor actuator and spring

from the tie rod pivot pin and set aside.

10 Remove the steer sensor assembly and set it

aside.

11 Using a soft metal drift pin and a mallet, drive

the pivot pin up to remove it.

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August 2022 Service and Repair Manual

Crushing hazard. The assembly
may become unbalanced and fall
if not properly supported and
secured with a suitable lifting
device when it is removed from
the machine.

Crushing hazard. The assembly
may become unbalanced and fall
if not properly supported and
secured with a suitable lifting
device when it is remove
the machine.

Component damage hazard.
Repairs to the motor should only
be performed by an authorized
dealer.

Component damage hazard. The
work area and surfaces where
this procedure will be performed
must be
that could get into the hydraulic
system and cause severe
component damage. Dealer
service is recommended.

Steer Axle Components

12 Remove the retaining fastener from the lower

yoke king pin.

How to Remove a Drive Motor

13 Use a small pry bar to remove the king pin.

14 Remove the retaining fastener from the upper

yoke king pin.

15 Use a small pry bar to remove the king pin.

16 Remove the yoke assembly from the

machine.

Right side yoke:

17 Remove the steer cylinder rue ring and clevis

pin from the yoke and set aside.

18 Remove the tie rod rue ring and clevis pin

from the yoke and set aside.

19 Remove the retaining fastener from the lower

yoke king pin.

20 Use a small pry bar to remove the king pin.

clean and free of debris

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

1 Refer to Repair Procedure, How to Remove

the Yoke.

2 Remove the drive motor mounting fasteners.

Remove the drive motor from the yoke.

21 Remove the retaining 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.

Part No. 1306586GT GS

d from

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Service and Repair Manual August 2022

Bodily injury hazard. Spraying
hydraulic
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Steer Axle Components

9-2 Steer Cyli nde r

9-2
Steer Cylinder

9-3 Tie Rod

9-3
Tie Rod

How to Remove the Steer
Cylinder

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

1 Tag, disconnect and plug the hydraulic hoses

from the steer cylinder. Cap the fittings on the
cylinder.

2 Remove the rue ring from each cylinder clevis

pin. Remove the clevis pins.

3 Remove the steer cylinder from the machine.

oil can penetrate and

How to Remove the Tie Rod

1 Remove the rue ring from the clevis pin

connecting the tie rod to the right side yoke
assembly. Remove the clevis pin.

1 clevis pin
2 pivot pin
3 steer sensor assembly
4 tie rod

2 Remove the retaining fasteners from the pivot

5 rue ring

pin connecting the tie rod to the left side yoke
assembly.

78 GS

3 Use a small pry bar to move the pivot pin

down enough to clear the steer sensor
assembly.

4 Remove the steer sensor actuator and spring

from the tie rod pivot pin and set aside.

5 Remove the steer sensor assembly and set it

aside.

6 Using a soft metal drift pin and a mallet, drive

the pivot pin up to remove it.

7 Remove the tie rod.

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Steer Axle Components

9-4 Oscillate Cyl i nde r

9-4
Oscillate Cylinder

9-5 Oscillate H oses

9-5
Oscillate Hoses

How to Remove the Oscillate
Cylinder

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

1 Tag, disconnect and plug the hydraulic hoses

from the oscillate cylinder. Cap the fittings on
the cylinder.

allow

2 Chock both sides of the wheels at the non-

steer end of the machine.

3 Center a lifting jack under the drive chassis

just behind the front axle on the side of the
machine the cylinder is being removed from.

Test the Oscillate Axle Hose
Routing

Note: Perform this procedure if the oscillate hoses
have been removed or replaced.

1 Open the ground controls compartment and

locate the function manifold.

4 Remove the pivot pin retaining fasteners.

5 Using a soft metal drift, remove the pivot pin.

Note: Adjust the lifting jack to reduce the load on
the pivot pins. Do not lift the machine off of the
ground.

6 Remove the oscillate cylinder from the

machine.

Part No. 1306586GT GS

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1 function manifold

Service and Repair Manual August 2022

Steer Axle Components

2 Disconnect the connector with the green/black

wire from the oscillate right coil (item 2) and
swap it with the connector with the blue wire
from the steer right coil (item 3).

1 Green
2 Green / Black
3 Blue
4 Blue / Black

3 Disconnect the connector with the green wire

from the oscillate left coil (item 1) and swap it
with the connector with the blue/black wire
from the steer left coil (item 4).

Check the Steering

1 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
controls.

2 Activate steer right and verify the machine

steers to the right.

3 Activate steer left and verify the machine

steers to the left.

Test the axle oscillate. Refer to Maintenance
Section, Test the Oscillate Axle.

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
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 retract.

6 Slowly drive the machine in a safe direction

and activate steer left.

7 Turn the key switch to the off position.

8 Swap the connectors back to the correct coils

using steps 2 an 3 as a reference. Continue to
Check the Steering.

80 GS

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August 2022 Service and Repair Manual

Steer Axle Components

9-6 Steer Angl e Se nsor

9-6
Steer Angle Sensor

How to Replace the Steer Angle
Sensor

The steer angle sensor, installed on the steer
yoke, is monitored by the control system to
determine steer angle. The control system uses
the steer angle input, along with pre-programmed
parameters, to vary the speed of each drive motor
while steering to minimize tire scrub and to help
minimize turning radius. Drive speed is also
reduced proportionately depending on the steer
angle to minimize lateral platform acceleration.

1 Adjust the 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 and turn the key switch to the off
position.

4 Remove the cable clamp securing the steer

sensor cable to the chassis.

5 Tag and disconnect the steer sensor harness

from the main harness.

6 Remove the steer sensor cover.

7 Remove the tie rod pivot pin retaining

fasteners.

1 left yoke assembly
2 steer sensor cover
3 compression spring
4 steer sensor actuator
5 tie rod pivot pin

8 Use a small pry bar to move the pivot pin

down enough to clear the steer sensor
assembly.

9 Remove the steer sensor actuator and spring

from the tie rod pivot pin and set aside.

Part No. 1306586GT GS

Note: Inspect the steer sensor actuator to make
sure it is not broken or twisted.

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Service and Repair Manual August 2022

Steer Axle Components

10 Remove the steer sensor assembly retaining

fasteners. Remove the steer sensor assembly
from the yoke.

11 Set the spacer plate aside.

12 Pull the sensor harness through the cable

restraint and sensor bracket.

13 Remove the retaining fasteners that secure

the steer sensor and the sensor spacer to the
mounting plate. Remove the steer sensor.

14 Install the new steer sensor.

15 Install the steer sensor assembly to the yoke.

16 Rotate the tie rod pivot pin until it is

approximately 90° from the mounting tab on
the tie rod.

1 steer sensor cover
2 spacer plate
3 steer sensor bracket
4 cable restraint
5 steer sensor
6 steer sensor spacer
7 steer sensor mounting plate

82 GS

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August 2022 Service and Repair Manual

Steer Axle Components

17 Install the steer sensor actuator onto the tie

rod pivot pin.

18 Insert the compression spring into the steer

sensor and push the tie rod pivot pin up until
the actuator hex pin is engaged into the steer
sensor.

Note: Be sure the sensor actuator hex pin is
engaged into the sensor.

19 Rotate the tie rod pivot pin counterclockwise

approximately 90° and secure it to the tie rod.

20 Install 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 Angle
Sensor.

How to Calibrate the Steer Angle
Sensor

1 Turn the key switch to the ground controls

position and pull out the red Emergency Stop
button to the on position at the platform
controls.

2 Press and hold the ground control scroll up

and scroll down buttons.

1 scroll down button
2 enter button
3 scroll up 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:

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Steer Axle Components

4 Release the Scroll Up and Scroll Down

buttons after the ground controller powers up.

5 At the ground controls, use the Scroll Down

button to scroll to SELECT OPTION.

10 Press the enter button.

Result: The ground controls LCD display will

show the following:

Note: The platform controls do not have to be
connected at the chassis ground controls.

6 Press the enter button.

7 Use the Scroll Up or Scroll Down buttons to

scroll to Select Option Steer Sensor.

8 Press the enter 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 buttons to

scroll to Calibrate Steer Sensor.

11 Press the enter button.

Result: The ground controls LCD display will

show the following:

12 Use the platform drive controller steer function

to align the steer tires with the drive chassis.

84 GS

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August 2022 Service and Repair Manual

Steer Axle Components

13 Press the enter button.

Result: The ground controls LCD display will

show the following:

14 Use the platform drive controller steer function

to turn the steer tires fully to 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 Press the enter button.

Result: The ground controls LCD display will

show the following:

Note: If any screens other than the one shown is
displayed, repeat this procedure. If the problem
persist, contact your local Genie Product Support.

18 Push in the red Emergency Stop button to the

off position.

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Electrocuti
Contact with electrically charged
circuits could result in death or
serious injury. Remove all rings,
watches and other jewelry.

Crushing hazard. The chassis
will fall if not properly

Non-steer Axle Components

Non-steer Axle Com p onen ts

10-1 Drive Motors

10-1
Drive Motors

How to Remove a Drive Motor

The drive motors are AC powered and are a
brushless design requiring very little maintenance.
They have built-in speed and temperature sensors
which is monitored by the ground controls
(GCON). The speed sensor is a Hall-effect type
and is part of the rear motor shaft bearing. The
temperature switch will shut down the drive motor
if it becomes excessively hot.

1 Disconnect the battery pack from the

machine.

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 wheel lug nuts. Do not remove

them.

5 Raise the machine approximately 2 inches /

5 cm. Place blocks under the chassis for
support.

on/burn hazard.

supported.

6 Remove the wheel lug bolts. Remove the tire

and wheel assembly.

7 Remove the axle cover.

1 axle cover
2 drive hub
3 axle assembly

8 Tag and disconnect the electrical connectors

for the brake, speed and temperature sensors
at the drive motor.

9 Tag and disconnect the electrical connectors

for the oscillate limit switches.

10 Tag and disconnect the drive motor power

cables from the motor controller in the ground
controls compartment.

Note: The power cables will have to be pulled
through the drive chassis when the axle assembly
is removed.

86 GS

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-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT

August 2022 Service and Repair Manual

Component damage hazard.
Repairs to the drive hub should
only be performed by an
authorized dealer.

Crushing hazard. The drive hu
may become unbalanced and fall
if not properly supported and
secured with a suitable lifting
device when removed from the
machine.

Non-steer Axle Components

11 Using a suitable supporting device, secure the

rear axle assembly. Do not apply pressure.

1 axle pivot pin
2 retaining 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.

10-2 Drive H ub

10-2
Drive Hub

How to Remove a Drive Hub

1 Remove the drive motor. Refer to Repair

Procedure, How to Remove a Drive Motor.

2 Using a suitable supporting device, secure the

drive hub. Do not apply pressure.

3 Remove the drive hub retaining fasteners.

Remove the drive hub.

b

1 axle assembly
2 drive hub
3 retaining fasteners (x4)
4 drive motor

14 Remove the retaining fasteners that secure

the drive motor to the drive hub.

15 Support and slide the drive motor shaft out of

the drive hub. Remove the drive motor from
the machine.

Note: There is an O-ring between the drive motor
and drive hub. Be sure that it is in place when
installing the drive motor to the drive hub.

Note: Refer to Specifications, Fastener Torque
Chart Specifications.

1 axle assembly
2 o-ring
3 retaining fasteners
4 drive hub

Part No. 1306586GT GS

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Service and Repair Manual August 2022

Bodily injury hazard. Spraying
hydraulic oil can penetrate and
burn skin. Loosen hydraulic
connections very slowly to allow
the oil pressure to dissipate
gradually. Do not allow oil to
squirt or spray.

Crushing hazard. The outrigger
cylinder may become
unb
properly supported when
removed from the machine.

Outrigger Components

Outrigge r C ompo ne nt s

11-1 Outrigge r Cyl in der

11-1
Outrigger Cylinder

How to Remove an Outrigger
Cylinder (if equipped)

Note: When removing a hose assembly or fitting,
the O-ring (if equipped) on the fitting and/or hose
end must be replaced. All connections must be
torqued to specification during installation. Refer to
Specifications, Hydraulic Hose and Fitting Torque
Specifications.

1 Remove the mounting fasteners from the

inside outrigger cylinder cover. Remove the
cover.

2 Remove the outrigger hose cover.

3 Disconnect the outrigger limit switch and

cylinder valve connectors.

4 Remove the mounting fasteners from the

outside outrigger cover. Remove the cover.

6 Attach a lifting strap from an overhead crane

to the barrel end of the outrigger cylinder for
support. Do not apply any lifting pressure.

7 Remove the outrigger mounting fasteners.

Slide the outrigger cylinder down and away
from the machine.

alanced and fall if not

Note: If the outrigger cylinder is being replaced,
remove the foot pad assembly and install it on the
replacement cylinder.

Note: After an outrigger cylinder has been
installed, the machine must be re-calibrated. Refer
to Repair Procedure, Outrigger Calibration.

5 Tag, disconnect and plug the hydraulic hoses

from the outrigger cylinder. Cap the fittings on
the cylinder.

88 GS

™

-2669 BE • GS™-3369 BE • GS™-4069 BE Part No. 1306586GT