Terex Genie GS-3369 BE User manual

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

Service Manual May 2015
Introduction
ii GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
Intr od ucti on Intr od ucti on
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate Operator's
Manual on your machine before attempting any
maintenance procedure.
This manual provides detailed scheduled
maintenance information for the machine owner
and user. It also 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
Machine Classification
Group B/Type 3 as defined by ISO 16368
Machine Design Life
Unrestricted with proper operation, inspection and
scheduled maintenance.
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 www.genielift.com
Use the links to locate Operator's, Parts or Service
Manuals.
Copyright © 2014 by Terex Corporation
1257106 Rev A, July 2014
First 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.

May 2015 Service Manual
Introduction
Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE iii
Revision History
Revision Date Section Procedure / Schematic Page / Description
A 7/2014 New release
A1 12/2014 Repair Added 12-2, Platform Overload Recovery
A2 4/2015 Maintenance C-2
Repair 3-5, 7-2
Schematics All Electrical and Hydraulic
A3 5/2015 Repair 5-4
Reference Examples:
Section – Maintenance, B-3
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Diagnostics, All charts
Section – Schematics, Legends and
schematics

Service Manual May 2015
Introduction
iv GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
Revision History
Revision Date Section Procedure / Page / Description
Reference Examples:
Section – Maintenance, B-3
Electronic Version
Click on any content or procedure in the Table of Contents to view
the update.
Section – Repair Procedure, 4-2
Section – Fault Codes, All charts
Section – Schematics, Legends and schematics

May 2015 Service Manual
Introduction
Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE v
Serial Number Legend
1 model
2 model year
3 facility code (for models manufactured in multiple facilities)
4 sequence code
5 serial label (stamped on chassis)
6 serial number (inside compartment)

Service Manual May 2015
Safety Rules
vi GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
Section 1 Safet y R ules
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 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.

May 2015 Service Manual
Safety Rules
Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE vii
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.
Read each procedure thoroughly. This
manual and the decals on the machine,
use signal words to identify the following:
Sa
fety alert symbol—
used to alert
personnel to potential 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 potenti
ally hazardous
situation which, if not avoided,
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 components when lifting or
placing loads. Always wear approved
steel
-toed shoes.
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.
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 tool
s and working areas
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
capab
le of supporting and stabilizing the
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
-locking
nuts) are not reused. These compon
ents
may fail if they are used a second time.
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.

May 2015
Table of Contents
viii GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
Introduction Introduction .......................................................................................................... ii
Important Information ..............................................................................................ii
Find a Manual for this Model...................................................................................ii
Revision History .....................................................................................................iii
Serial Number Legend ........................................................................................... v
Section 1 Safety Rules......................................................................................................... vi
General Safety Rules .............................................................................................vi
Section 2Specifications....................................................................................................... 1
Machine Specifications .......................................................................................... 1
Performance Specifications ................................................................................... 2
Hydraulic Specification........................................................................................... 2
Hydraulic Component Specifications ..................................................................... 5
Manifold Component Specifications....................................................................... 5
Battery Specifications ............................................................................................ 6
Kohler KD350 Engine Specifications ..................................................................... 7
Hydraulic Hose and Fitting Torque Specifications ................................................. 8
Torque Procedure .................................................................................................. 9
SAE and Metric Fasteners Torque Charts........................................................... 11

May 2015
Table of Contents
Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE ix
Section 3 Scheduled Maintenance Procedures ...............................................................13
Introduction...........................................................................................................13
Pre-Delivery Preparation Report ..........................................................................17
Maintenance Inspection Report............................................................................19
Checklist A Procedures .....................................................................................21
A-1 Inspect the Manuals and Decals....................................................................21
A-2 Perform Pre-operation Inspection..................................................................22
A-3 Perform Function Tests .................................................................................22
A-4 Perform Engine Maintenance ........................................................................23
A-5 Test the Oscillate Axle ...................................................................................23
A-6 Perform 30 Day Service.................................................................................24
A-7 Perform Engine Maintenance ........................................................................24
A-8 Replace the Drive Hub Oil .............................................................................25
Checklist B Procedures .....................................................................................26
B-1 Inspect the Batteries ......................................................................................26
B-2 Inspect the Electrical Wiring ..........................................................................28
B-3 Inspect the Tires, Wheels and Castle Nut Torque.........................................29
B-4 Perform Engine Maintenance ........................................................................29
B-5 Test the Emergency Stop ..............................................................................30
B-6 Test the Key Switch .......................................................................................30
B-7 Test the Automotive-style Horn (if equipped) ................................................31
B-8 Test the Drive Brakes ....................................................................................31
B-9 Test the Drive Speed - Stowed Position........................................................32
B-10 Test the Drive Speed - Raised Position.......................................................32
B-11 Check the Electrical Contactor ....................................................................33
B-12 Perform Hydraulic Oil Analysis ....................................................................33
B-13 Inspect the Fuel and Hydraulic Tank Cap Venting Systems .......................34
B-14 Check the Drive Hub Oil Level and Fastener Torque..................................35

May 2015
Table of Contents
x GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
Checklist C Procedures..................................................................................... 36
C-1 Test the Platform Overload System (if equipped) ......................................... 36
C-2 Down Limit Switch Descent Delay (if equipped) ........................................... 37
Check the Down Limit Switch Rocker Arm Orientation (if equipped) ............. 37
Check the Descent Delay Function ................................................................ 38
Check the Down Limit Switch Height.............................................................. 38
C-3 Replace the Hydraulic Tank Breather Cap -
Models with optional Hydraulic Oil ............................................................... 38
C-4 Perform Engine Maintenance........................................................................ 39
Checklist D Procedures..................................................................................... 40
D-1 Check the Scissor Arm Wear Pads and Slider Blocks.................................. 40
D-2 Replace the Drive Hub Oil............................................................................. 40
D-3 Test the Function Pump ................................................................................ 41
Checklist E Procedures..................................................................................... 42
E-1 Test or Replace the Hydraulic Oil.................................................................. 42
E-2 Grease the Steer Axle Wheel Bearings ........................................................ 43

May 2015
Table of Contents
Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE xi
Section 4 Repair Procedures .............................................................................................45
Introduction...........................................................................................................45
Platform Controls ...............................................................................................47
Operational Indicator Codes ...........................................................................47
1-1 Circuit Board...................................................................................................48
1-2 Joystick...........................................................................................................49
1-3 Platfrom Controls Alarm .................................................................................49
1-4 Platfrom Emergency Stop Button...................................................................50
Platform Components........................................................................................51
2-1 Platform ..........................................................................................................51
2-2 Platform Extension Deck................................................................................52
Scissor Components .........................................................................................54
3-1 Scissor Assembly, GS-2669 BE ....................................................................55
3-2 Scissor Assembly, GS-3369 BE ....................................................................58
3-3 Scissor Assembly, GS-4069 BE ....................................................................62
3-4 Wear Pads......................................................................................................65
3-5 Lift Cylinders...................................................................................................67
Engines................................................................................................................69
4-1 Oil Pressure Switch........................................................................................69
How to Replace the Oil Pressure Switch .........................................................69
How to Repair the Kohler KD350 Engine........................................................69

May 2015
Table of Contents
xii GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
Ground Controls ................................................................................................ 70
5-1 Software Revision Level ................................................................................ 71
5-2 Machine Setup ............................................................................................... 72
5-3 Auxiliary Platform Lowering ........................................................................... 73
5-4 Level Sensor - Models without Outriggers..................................................... 73
5-5 Level Sensor - Models with Outriggers.......................................................... 76
5-6 Service Override Mode .................................................................................. 78
Hydraulic Pump.................................................................................................. 80
6-1 Hydraulic Pump ............................................................................................. 80
How to Test the Hydraulic Pump .................................................................... 80
How to Remove the Hydraulic Pump.............................................................. 80
How to Calibrate the Hydraulic Pump............................................................. 81
Manifolds ............................................................................................................ 83
7-1 Function Manifold Components ..................................................................... 83
7-2 Valve Adjustments - Function Manifold ......................................................... 85
How to Adjust the System Relief Valve .......................................................... 85
How to Adjust the Oscillate Relief Valve ........................................................ 86
How to Adjust the Steer Relief Valve.............................................................. 87
How to Adjust the Platform Up Relief Valve -
Models with Platform Overload ............................................................... 88
How to Adjust the Platform Up Relief Valve -
Models without Platform Overload .......................................................... 93
7-3 Outrigger Manifold Components.................................................................... 95
7-4 Valve Coils ..................................................................................................... 96
How to Test a Coil Diode ................................................................................ 97

May 2015
Table of Contents
Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE xiii
Fuel and Hydraulic Tanks..................................................................................98
8-1 Fuel Tank .......................................................................................................98
8-2 Hydraulic Tank ...............................................................................................99
Steer Axle Components...................................................................................100
9-1 Yoke Assembly ............................................................................................100
9-2 Steer Cylinder ..............................................................................................102
9-3 Tie Rod.........................................................................................................102
9-4 Oscillate Cylinder .........................................................................................103
9-5 Oscillate Hoses ............................................................................................103
9-6 Steer Angle Sensor ......................................................................................105
How to Calibrate the Steer Angle Sensor .....................................................107
Non-steer Axle Components ...........................................................................110
10-1 Drive Motors ...............................................................................................110
10-2 Drive Hub ...................................................................................................112
Outrigger Components ....................................................................................113
11-1 Outrigger Cylinder ......................................................................................113
11-2 Outrigger Calibration ..................................................................................114
How to Calibrate the Outrigger System ........................................................114
Platform Overload Components .....................................................................116
12-1 Platform Overload System .........................................................................116
How to Calibrate the Platform Overload System ..........................................116
Check the Maximum Height Limit Switch......................................................117
Platform Overload System Troubleshooting .................................................119
12-2 Platform Overload Recovery ......................................................................120
How to Clear the Platform Overload Recovery Message .............................120
Battery Charger ................................................................................................122
13-1 Battery Charger ..........................................................................................122

May 2015
Table of Contents
xiv GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
Section 5 Fault Codes....................................................................................................... 125
Introduction ........................................................................................................ 125
Operation Indicator Codes (OIC) ....................................................................... 130
Diagnostic Trouble Codes (DTC)....................................................................... 130
Troubleshooting "HXXX" and "PXXX" Faults..................................................... 131
Fault Inspection Procedure ................................................................................ 132
Type "HXXX" Faults ........................................................................................... 134
Type "PXXX" Faults ........................................................................................... 137
Type "UXXX" Faults ........................................................................................... 140
Type "FXXX" Faults ........................................................................................... 142
Type "CXXX" Faults ........................................................................................... 145

May 2015
Table of Contents
Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE xv
Section 6 Schematics........................................................................................................147
Introduction.........................................................................................................147
Electrical Component and Wire Color Legends .................................................148
Hydraulic Component Legend............................................................................151
Electrical Symbols Legend .................................................................................152
Hydraulic Symbols Legend.................................................................................153
Limit Switch Legend ...........................................................................................154
Charger Interlock ................................................................................................155
Contactor Box Layout, All Models ......................................................................158
Ground Control Box Layout, All Models .............................................................159
Platform Control Box Layout, All Models............................................................162
Generator Wiring Diagram, All Models...............................................................163
Electrical Schematic, GS-2669 BE and GS-3369 BE
with 2 Speed Lift, (ANSI / CSA)..................................................................166
Electrical Schematic, GS-2669 BE and GS-3369 BE
with Proportional Lift, (ANSI / CSA)............................................................167
Electrical Schematic, GS-4069 BE with 2 Speed Lift, (AS / CE)........................170
Electrical Schematic, GS-4069 BE with Proportional Lift, (ANSI / CSA)............171
Electrical Schematic, GS-2669 BE and GS-3369 BE
with 2 Speed Lift, (AS / CE)........................................................................174
Electrical Schematic, GS-2669 BE and GS-3369 BE
with Proportional Lift, (AS / CE)..................................................................175
Electrical Schematic, GS-4069 BE with 2 Speed Lift, (AS / CE)........................178
Electrical Schematic, GS-4069 BE with Proportional Lift, (AS / CE)..................179
Hydraulic Schematic, GS-2669 BE and GS-3369 BE with 2 Speed Lift ............182
Hydraulic Schematic, GS-2669 BE and GS-3369 BE with Proportional Lift ......183
Hydraulic Schematic, GS-4069 BE with 2 Speed Lift.........................................186
Hydraulic Schematic, GS-4069 BE with Proportional Lift...................................187

May 2015
Table of Contents
xvi GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
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May 2015 Service Manual
Specifications
Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE 1
Section 2 Speci fi c ati ons
Machine Specifications
Fluid capacities
Hydraulic tank
(maximum fill capacity)
16.5 g
allons
62.5 liters
Hydraulic system
without outriggers
(including tank), GS
-2669 BE
16.5 g
allons
62.5 liters
Hydraulic system with outriggers
(including tank), GS
-2669 BE
18 g
allons
68 l
iters
Hydraulic system without outriggers
(including tank), GS
-3369 BE
16.5 g
allons
62.5 liters
Hydraul
ic system with outriggers
(including tank), GS
-3369 BE
18 g
allons
68 l
iters
Hydraulic system without outriggers
(including tank), GS
-4069 BE
17.5 g
allons
66 l
iters
Hydraulic system with outriggers
(including tank), GS
-4069 BE
19 g
allons
72 l
iters
Drive
hub
EP 9
0 or SAE 90 multipurpose hypoid
gear oil API service classification GL5
24.5 o
unces
0.7 liters
Fuel tank
3.3 g
allons
12.5 liters
Tires and wheels
Wheel lugs (steer end)
9 @ 5/8-
18
Lug nut torque, dry
90 ft-
lbs
122 Nm
Lug nut torque,
lubricated 68 ft-
lbs
92 Nm
Wheel lugs (non
-steer end) 9 @ 5/8-
18
Lug nut torque, dry
170 ft-
lbs
230 Nm
Lug nut torque, lubricated
130 ft-
lbs
176 Nm
Castle nut (steer end)
Castle nut torque
35 ft-
lbs
47.5 Nm
Non-marking, foam filled, RT
Tire
size 26 x
12D380
Tire ply rating
8
Tire diameter
26 i
n
66 c
m
Tire width
12 i
n
30 c
m
Weight, each
177.5 l
bs
80.5 k
g
For operational specifications, refer to the
Operator's Manual.

Service Manual May 2015
Specifications
2 GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
Performance Specifications
Drive speed, maximum
Platform stowed
Forward direction
4.5 m
ph
7.2 k
m/h
40 ft / 6.1 s
ec
12.2 m / 6.1 s
ec
Platform stowed
Reverse direction
3.0 m
ph
1.8 k
m/h
40 ft / 9.1 s
ec
12.2 m / 9.1 s
ec
Platform raised
0.3 m
ph
0.5 k
m/h
40 ft / 91 s
ec
12.2 m / 91 s
ec
Braking distance, maximum
High range on paved surface
less than 3 f
t
less than 0.9
m
Gradeability
See Operator's Manual
Function speed, maximum from platform controls
(with maximum rated load in platform)
GS-2669 BE
Platform up
Platform down
29 to 39 s
econds
GS-3369 BE
Platform up
Platform down
29 to 39 s
econds
GS-4069 BE
Platform up
Platform down
34 t
o 44seconds
Outrigger leveling, maximum
Front
Back
Side to side
5.3°
4.2°
11.7°
Hydraulic Specifications
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
conditioning, and foam and aeration suppression
properties.
Cleanliness level,
minimum
ISO 15/13
Water content,
maximum
250 p
pm
Recommended Hydraulic Fluid
Hydraulic oil type
Chevron
Rando HD Premium
Viscosity grade
32
Viscosity index
200
Optional Hydraulic Fluids
Mineral based
Shell Tellus S2 V 32
Shell Tellus S2 V 46
Chevron 5606A
Biodegradable
Petro Canada Environ MV
46
Fire resistant
UCON Hydrolube HP-
5046
Note: Genie specifications require additional
equipment and special installation instructions for
the approved optional fluids. Consult Genie
Product Support before use.
Optional fluids may not have
the same hydraulic lifespan and
may result in component
damage.
Note: Extended machine operation can cause the
hydraulic fluid temperature to increase beyond it's
maximum allowable range. If the hydraulic fluid
temperature consistently exceeds 200°F / 90°C an
optional oil cooler may be required.

May 2015 Service Manual
Specifications
Part No. 1257106 GS-2669 BE • GS-3369 BE • GS-4069 BE 3
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, filters,
control valves and may result in
component damage.
Note: Do not operate the machine when the
ambient air temperature is consistently above
120°F / 49°C.
Hydraulic Fluid Temperature
Range
Ambient air temperature
1 Chevron hydraulic oil 5606A
2 Petro-Canada Environ MV 46
3 UCON Hydrolube HP-5046D
4 Chevron Rando HD premium oil MV
Chevron Rando HD Premium Oil
MV Fluid Properties
ISO Grade
32
Viscosity index
200
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
7.5
33.5
Brookfield Viscosity
cP @
-4°F / -20°C
cP @
-22°F / -30°C
1040
3310
Flash point
375°F / 190°C
Pour point
-58°F / -
50°C
Maximum continuous operating
temperature
171°F / 77°C
Note: An 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.
Chevron 5606A Hydraulic Oil
Fluid Properties
ISO Grade
15
Viscosity index
300
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F
/ 40°C
cSt @
-40°F / -40°C
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
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.

Service Manual May 2015
Specifications
4 GS-2669 BE • GS-3369 BE • GS-4069 BE Part No. 1257106
Continued use of Chevron
5606A hydraulic fluid, or
equivalent, when ambient
temperatures are consistently
above 32°F / 0°C may result in
component damage
Petro-Canada Environ MV 46
Fluid Properties
ISO Grade
46
Viscosity index
154
Kinematic Viscosity
cSt @ 200°F / 100°C
cSt @ 104°F / 40°C
8.0
44.4
Flash point
482°F / 250°C
Pour point
-49°F / -
45°C
Maximum continuous operating
temperature
180°F / 82°C
UCON Hydrolube HP-5046 Fluid
Properties
ISO Grade
46
Viscosity index
192
Kinematic Viscosity
cSt @ 149°F / 65°C
cSt @ 104°F / 40°C
cSt @ 0°F /
-18°C
22
46
1300
Flash point
None
Pour point
-81°F / -
63°C
Maximum continuous operating
temperature
189°F / 87°C