Genie GS-69 Series User manual

SAFETY NOTICE 110008
Terex Aerial Work Platform, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
1 of 2
Date: November 17, 2011
Models GS-2669
GS-3369
GS-4069
Serial Numbers Affected: GS6911-101 to GS6912-412
Subject: Machine Instability
Allowable Hours: 1 hour
Issue:
Genie has determined that some of the machines in the serial range listed above may have been
manufactured incorrectly in the following ways:
•The hydraulic circuit in the oscillation system may have been assembled incorrectly causing
the oscillating axles to function improperly. Improperly functioning oscillating axles can
result in loss of machine stability.
•Axle pivot pins that are out of specifications may have been installed, allowing the axles to
be partially supported. Axles that are partially supported can result in loss of machine
stability.
Action Required:
This notice requires the removal of all affected machines from service until the following
actions are completed:
•Rewiring and replumbing of the oscillate system
•Inspection of the axle pivot pins
1. Locate all machines within the model and serial numbers given above.
2. Inspect the axle pivot pins and oscillate system using the enclosed instructions.
3. Fill out and sign the Completion Form included in the Inspection and Repair instructions and
return to Genie. This will verify that this safety notice has been completed on your machine.

SAFETY NOTICE 110008
Terex Aerial Work Platform, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
2 of 2
Warranty:
The labor and travel miles required to perform this inspection and installation are covered under the
provisions of our warranty agreement. Labor for each affected machine will be paid at a rate of
$60.00 U.S. per hour and travel at a rate of $.50 U.S. per mile, converted into the currency of the
appropriate country at the time of payment.
If you are the owner of an affected machine and are not an authorized Genie dealer, please
contact your nearest Genie dealer for assistance with this safety notice. Only Genie
Authorized Dealers will be reimbursed for labor or any other costs associated with this
bulletin under the provisions of our standard warranty terms and conditions.
Genie and ANSI requires that the seller of a Genie machine report to Genie the model and serial
number of each machine sold, as well as the name, address, and telephone number of the new
owner, within 60 days of the sale. OSHA and ANSI also require that the manufacturer’s safety
notices be completed. It is your responsibility to communicate this important information to all
machine owners and applicable branches. If you require additional copies of this safety notice or
have any questions, please contact Genie’s service department at:
United States 800-536-1800
Canada 425-881-1800
Europe [phone]
Australia 61 733751660
All other locations 001-425-881-1800
Enclosures:
Machine List Report
New Owner Update Form
Inspection and Repair Instructions

Terex Aerial Work Platform, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
Safety Notice 110008
New Owner Update Form
(for updating machine owner information only)
Local Norms and Regulations require that the seller of a Genie machine report to Genie the model and
serial number of each machine sold, as well as the name, address, and telephone number of the new
owner, within 60 days of the sale.
•If you have sold a machine, list the complete model and serial number (example: GS6911-136 or
GS6912-364)and the name, address and phone number of the new owner.
New Owner Information:
Machine 1 Machine 2 Machine 3
Model*
Serial Number*
Owner Name*
Address 1*
Address 2
City/State/Zip*
Phone Number*
Contact Person
* Required fields.
Seller Information:
Date:
Company Name:
Account #:
Address:
(street)
(city)
State, zip code
Phone #:
•List any machines that could not be inspected or repaired because of the following:
Model & Serial Number Scrapped Exported Stolen Others (explain)
- - - -
- - - -
- - - -
- - - -
Fax to: United States 877-738-7530
Canada 425-498-7530
All other locations 001-425-498-7530

REV A
2 GS-69 RT Models Part No. 237339
Inspection and Repair Instructions
Introduction
Observe and Obey:
This procedure 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 Starting Installation:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual.
Be sure that all necessary tools and parts are
available and ready for use.
Read this procedure completely and adhere
to the instructions. Attempting shortcuts may
produce hazardous conditions.
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.
Tools required:
7/16 socket
9/16 socket
Ratchet
Small flathead screwdriver
or pick
9/16 wrench
11/16 wrench
Volt meter
Measuring tape or ruler
Hydraulic caps and plugs
Note: These installation instructions only
apply to the Genie models listed below, as
required by Safety Notice 110008.
• GS-2669
• GS-3369
• GS-4069

REV A
Part No. 237339 GS-69 RT Models 3
Inspection and Repair Instructions
Instructions
• Record the model and serial number.
• Place a "N" (No) in the appropriate box if repairs were not required.
• Place a "Y" (Yes) in the appropriate box if repairs were required.
Model
Serial number
Ground Control Box
Axle Limit Switches
Oscillate Hose Routing
Axle Pins
Model
Serial number
Ground Control Box
Axle Limit Switches
Oscillate Hose Routing
Axle Pins
Model
Serial number
Ground Control Box
Axle Limit Switches
Oscillate Hose Routing
Axle Pins
Model
Serial number
Ground Control Box
Axle Limit Switches
Oscillate Hose Routing
Axle Pins
Model
Serial number
Ground Control Box
Axle Limit Switches
Oscillate Hose Routing
Axle Pins
Inspection Check List

REV A
4 GS-69 RT Models Part No. 237339
Inspection and Repair Instructions
Procedure
Note: Perform this procedure on a firm, level
surface with the machine in the stowed position. At
the ground control box, turn the key switch to the
off position and push in the red Emergency Stop
button.
Ground Control Box
1 On the ground controls side of the machine,
open the compartment door.
2 Remove the retaining fastener that secures the
ground control panel and set aside. Open the
control box. Refer to illustration 1, item A.
illustration 1
3 Locate the ECU (U5) in the control box. Trace
the white wire from connector J2 pin C8 to the
terminal strip. Refer to illustration 2.
4 Trace the white/black wire from connector J2
pin C9 to the terminal strip.
Refer to illustration 2.
If the white wire is located in terminal strip 11
and the white/black is in 6. Continue to Axle
Limit Switches.
The wires are in the incorrect location.
Continue with step 5.
illustration 2
5 Correct the location of the 2 wires in the
terminal strip. Continue to Axle Limit
Switches.
Note: Do not close the control box at this time.
A
G6
P1
CB7
CB2
J1
J2
U5
KS1
H5
CR72
CR9
CR4
CR10
CR15CR2
CR17
CR5CR1CR71CR62
C1
1 2 3 4 5 6 7 8 9 10111213141516171819202122232425262728293031323334353637383940414243444546474849505152535455565758
D
C
B
A
J5
J6J7
J8
J9
J10
J11
J12
J2-C8
WH
J2-C9
WH/BK
WH
WH/BK

REV A
Part No. 237339 GS-69 RT Models 5
Inspection and Repair Instructions
Axle Limit Switches
1 At the non-steer end of the machine, locate and
remove both axle covers. Set the covers and
retaining fasteners aside. Refer to illustration 3
item A.
illustration 3
2 At the ground controls side of the machine
locate the 2 oscillate limit switch harnesses
located in the non-steer axle. Refer to
illustration 4, item A.
illustration 4
A
3 Locate the 3 pin connector harness. Using a
volt meter, check continuity from the black wire
in pin C to J5 pin 12 at the ground control box.
Refer to illustration 2 for the J5 location.
There is good continuity. Continue to step 5.
There is no continuity. Continue with step 4.
4 Swap the 3 pin harness with the one on the
engine side of the machine in the non-steer
axle and repeat step 3.
Note: If there is still no continuity after repeating
step 3 check the meter lead connections and
meter setting.
5 Locate the 4 pin connector harness. Using a
volt meter, check continuity from the white wire
in pin 4 to J12 pin 6 at the ground control box.
Refer to illustration 2 for the J12 location.
There is good continuity. Continue to step 7.
There is no continuity. Continue with step 6.
6 Swap the 4 pin harness with the one on the
engine side of the machine in the non-steer
axle and repeat step 5.
Note: If there is still no continuity after repeating
step 5 check the meter lead connections and
meter setting.
7 Install the axle covers and securely tighten the
retaining fasteners. Do not over tighten.
8 Close the ground control box. Continue to
Oscillate Hose Routing.
PROCEDURE
A

REV A
6 GS-69 RT Models Part No. 237339
Inspection and Repair Instructions
PROCEDURE
Oscillate Hose Routing
1 Turn the key switch to platform controls and
pull out the red Emergency stop buttons to the
on position at both the ground and platform
controls. Start the engine.
2 Raise the platform to approximately 10 ft / 3 m.
3 Lift the safety arm and move it to the center of
the linkage and rotate to a vertical position.
4 Lower the platform onto the safety arm.
5 Turn the machine off.
6 Locate and remove the chassis hose cover and
set aside. Refer to illustration 5, item A.
illustration 5
7 Open the ground controls compartment and
locate the function manifold. Refer to
illustration 6, item A.
illustration 6
8 At the steer end of the machine locate the 2
oscillate cylinders. Refer to illustration 7,
item A.
illustration 7
A
ALEFT
RIGHT
B
A

REV A
Part No. 237339 GS-69 RT Models 7
Inspection and Repair Instructions
Axle Pins
Non-steer end:
1 At the non-steer end of the machine locate the
2 axle pivot pins. Refer to illustration 9,
item A.
illustration 9
2 Measure the distance from the chassis
bulkhead to the tapered end of the pivot pin
towards the center of the machine. Refer to
illustration 10.
It measures 0.250 inches / 6.35 mm or greater.
Continue with step 3.
The pivot pin is less than specified. Tag and
remove the machine from service. Contact the
Genie parts department for a replacement pin
kit. You must reference Safety Notice 110008
when ordering. Continue to the Steer end pin
inspection.
Note: If the pivot pins need to be replaced do not
continue to section Test the Oscillate Axle until
the pins have been replaced.
9 Using illustration 8 as a guide, verify that the
oscillate hoses are routed correctly from the
function manifold to the oscillate cylinders.
The hoses are routed correctly. Continue to
Axle Pins.
The hoses are not routed correctly. Continue
with step 10.
illustration 8
10 Remove the cylinder cover from the oscillate
cylinder and correct the hose routing. Refer to
illustration 7, item B.
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.
11 Install the cylinder cover. Continue to Axle
Pins.
Note: Do not install the chassis hose cover or
lower the platform at this time.
A
RIGHT
OSC. CYLINDER
FUNCTION
MANIFOLD
OSCL
OSCR
LEFT
OSC. CYLINDER
E
R
E
R
PROCEDURE

REV A
8 GS-69 RT Models Part No. 237339
Inspection and Repair Instructions
PROCEDURE
illustration 10
Steer end:
3 At the steer end of the machine locate the axle
pivot pin. Refer to illustration 11, item A.
illustration 11
4 Measure the distance from the chassis
bulkhead to the tapered end of the pivot pin
towards the center of the machine. Refer to
illustration 12.
It measures 0.250 inches / 6.35 mm or greater.
Continue with step 5.
The pivot pin is less than specified. Tag and
remove the machine from service. Contact the
Genie parts department for a replacement pin
kit. You must reference Safety Notice 110008
when ordering.
Note: If the pivot pin needs to be replaced do not
continue to section Test the Oscillate Axle until
the pin has been replaced. Do not install the
chassis hose cover at this time. It will need to be
removed during pin replacement. Lower the
platform to the stowed position.
illustration 12
A

REV A
Part No. 237339 GS-69 RT Models 9
Inspection and Repair Instructions
5 Install the chassis hose cover removed in step
6 of the Oscillate Hose Routing section.
6 Turn the key switch to platform controls and
pull out the red Emergency stop buttons to the
on position at both the ground and platform
controls. Start the engine.
7 Raise the platform to approximately 10 ft / 3 m.
8 Return the safety arm to the cradle.
9 Lower the platform to the stowed position.
Continue to Test the Oscillate Axle.
Test the Oscillate Axle
Note: Genie specifications require that this
procedure be performed daily or every 8 hours,
whichever comes first.
Proper axle oscillation is essential to safe machine
operation. If the axle oscillation system is not
operating correctly, the stability of the machine is
compromised and it may tip over.
1 Start the engine from the platform controls.
Select the high idle function.
Test the Oscillate System (stowed position):
2 Drive the left front wheel up onto a 4 in / 10 cm
high ramp.
Result: The three remaining tires should stay in
firm contact with the ground.
3 Drive the right steer tire up onto a 4 in / 10 cm
high ramp.
Result: The three remaining tires should stay in
firm contact with the ground.
If the oscillate system does not operate as
stated, do not proceed. Re-check the wiring,
limit switches and hydraulic hoses.
Test the Oscillate System (elevated position):
4 Push and hold the lift function enable button
and raise the platform between 7 ft / 213 cm to
9 ft / 274 cm.
PROCEDURE

REV A
10 GS-69 RT Models Part No. 237339
Inspection and Repair Instructions
5 Drive the left front wheel up onto a 4 in / 10 cm
high ramp.
Result: The three remaining tires should stay in
firm contact with the ground.
6 Drive the right steer tire up onto a 4 in / 10 cm
high ramp.
Result: The three remaining tires should stay in
firm contact with the ground.
7 Perform function test. Refer to the Operator's
Manual on your machine.
8 Return the machine to service.
9 Important: You must complete and submit the
attached completion form to Genie's Warranty
department to update machine serial number
records. Your warranty claims will not be
processed without this completion form. This
will serve as verification that you have
completed Safety Notice 110008.
If you have any further questions regarding these
instructions or need assistance, please contact the
Genie Service Department at one of the following
telephone numbers:
United States: 800-536-1800
Canada: 425-881-1800
Europe: UK 0044 1476 584 333
France 0033 237 260 986
Germany 49 4221 491 821
Iberica 0034 935 725 090
Italy 0039 075 941 8171
Scandinavia 0046 3157 5154
Other locations 0031 653 221 908
Middle East: 0097 143 391 800
or 0097 150 459 7937
Australia: 61 7 3456 4444
All other locations 001-425-881-1800
PROCEDURE

Terex Aerial Work Platform, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-
1800
Safety Notice 110008
Completion Form
Your signature on this form will verify that you have performed the indicated modifications on
the serial numbers listed below. List the complete serial number of the machine (ex. GS6911-
136 or GS6912-364). Please check all that apply.
Model: __________________________ Model: ____________________________
Serial Number :____________________ Serial Number: _____________________
Oscillate System: Oscillate System:
rewired the ground control box rewired ground control box
rewired the limit switches rewired the limit switches
rerouted oscillate hoses rerouted oscillate hoses
Axle Pivot Pins Axle Pivot Pins
replaced 1 non-steer end pin replaced 1 non-steer end pin
replaced 2 non-steer end pins replaced 2 non-steer end pins
replaced steer-end pin replaced steer-end pin
Model: __________________________ Model: ____________________________
Serial Number :____________________ Serial Number: _____________________
Oscillate System: Oscillate System:
rewired the ground control box rewired ground control box
rewired the limit switches rewired the limit switches
rerouted oscillate hoses rerouted oscillate hoses
Axle Pivot Pins Axle Pivot Pins
replaced 1 non-steer end pin replaced 1 non-steer end pin
replaced 2 non-steer end pins replaced 2 non-steer end pins
replaced steer-end pin replaced steer-end pin
Date:
Company Name:
Account #:
Address:
(street)
(city)
State, zip code
Phone #:
Fax to: United States 877-738-7530
Canada 425-498-7530
All other locations 001-425-498-7530
Signature (Service Manager)

Terex Aerial Work Platform, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-
1800
Safety Notice 110008
Completion Form for Inspection
Your signature on this form will verify that you have performed the inspection per Safety Notice
110008 and verified that the machines listed below do not need any modification.
Please list the complete model and serial (ex. GS6911-136 or GS6912-364)
___________________________ ____________ ____________
Service Manager (Print) Signature Date
Fax to: United States 877-738-7530
Canada 425-498-7530
All other locations 001-425-498-7530
Model & Serial Number Model & Serial Number
Owner Information:
Date:
Company Name:
Account #:
Address:
(street)
(city)
State, zip code
Phone #: