Genie GS-3384 Service Manual
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Genie GS-3384 Service Manual

From serial number 40001 to gs8405-40832
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See also: Service & Repair Manual , Maintenance Manual
Service Manual
(from serial number 40001 to GS8405-40832)
Part No. 82259
Rev D
September 2005

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Summary of Contents for Genie GS-3384

  • Page 1 Service Manual Part No. 82259 Rev D September 2005 (from serial number 40001 to GS8405-40832)

  • Page 2: Introduction

    Technical Publications Genie Industries 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.

  • Page 3: Serial Number Legend

    Maximum number of platfrm occupants: Year of manufacture Country of manufacture: USA Facility code This machine complies with: (if applicable) ANSI A92.6-1999 B354.2-01 Genie Industries 18340 NE 76th Street Redmond, WA 98052 PN - 77055 Part No. 82259 GS-3384...
  • Page 4 September 2005 This page intentionally left blank. GS-3384 Part No. 82259...

  • Page 5: Safety Rules

    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. 82259 GS-3384...
  • Page 6 These components or maintenance information. 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 . GS-3384 Part No. 82259...

  • Page 7: Table Of Contents

    A-5 Check the Engine Coolant Level - GM Models ........3 - 9 A-6 Inspect the Engine Air Filter - GM Models .......... 3 - 9 A-7 Check the Battery - GM Models ............3 - 10 A-8 Inspect the Radiator - GM Models ............ 3 - 12 Part No. 82259 GS-3384...
  • Page 8 B-16 Test the Drive Speed - Raised Position ..........3 - 30 B-17 Perform Hydraulic Oil Analysis ............3 - 31 B-18 Replace the Medium and High Pressure Hydraulic Filter Elements .. 3 - 31 GS-3384 Part No. 82259 viii...
  • Page 9 E-3 Perform Engine Maintenance - Deutz 1011F Models ....... 3 - 59 E-4 Perform Engine Maintenance - Ford Models ........3 - 60 E-5 Perform Engine Maintenance - Deutz Models ........3 - 60 E-6 Perform Engine Maintenance - Deutz 2011 Models ......3 - 60 Part No. 82259 GS-3384...
  • Page 10 Platform Components Platform ................... 4 - 15 Platform Extension Deck ..............4 - 17 Scissor Components Scissor Assembly, GS-3384 ............4 - 18 Wear Pads ..................4 - 24 Lift Cylinder ..................4 - 26 Engines RPM Adjustment ................4 - 28 Engine Fault Codes - Ford Models ...........
  • Page 11 Steer Cylinder .................. 4 - 85 Tie Rod .................... 4 - 85 Non-steer Axle Components 10-1 Drive Motor and Brake ..............4 - 86 10-2 Drive Hub ..................4 - 87 Outrigger Components 11-1 Outrigger Cylinder ................4 - 88 Part No. 82259 GS-3384...
  • Page 12 (after serial number GS8403-40212) ............5 - 5 Ford Engine ECM Fault Code Chart (before serial number GS8404-40302) ............5 - 8 Ford Engine ECM Fault Code Chart (after serial number GS8404-40301) ............5 - 10 GS-3384 Part No. 82259...
  • Page 13 (after serial number GS8403-40212) ............6 - 32 Electrical Schematic - ANSI Models with Ford Power (before serial number GS8404-40302) ............6 - 36 Electrical Schematic - ANSI Models with Ford Power (from serial number GS8404-40302 to GS8405-40504) ......6 - 40 Part No. 82259 GS-3384 xiii...
  • Page 14 (from serial number GS8405-40505 to GS8405-40832) ......6 - 100 Hydraulic Schematics Component Call-out and Symbols Legend ... 6 - 103 Hydraulic Schematic (before serial number GS8404-40297) ............ 6 - 104 Hydraulic Schematic (from serial number GS8404-40297 to GS8405-40832) ......6 - 106 GS-3384 Part No. 82259...

  • Page 15: Machine Specifications

    190 kg ( 4.5 kg) Weight, air-filled 157 lbs 71.2 kg Pressure, air-filled 38 psi 2.6 bar Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 82259 GS-3384 2 - 1...

  • Page 16: Performance Specifications

    Rated work load at full height, maximum mixable with Shell Donax TG (Dexron III) oils. GS-3384 2500 lbs Genie specifications require hydraulic oils which are 1135 kg designed to give maximum protection to hydraulic systems, have the ability to perform over a wide...
  • Page 17 Hydraulic tank 10 micron with return line filter 25 psi / 1.7 bar bypass Continuous improvement of our products is a Genie policy. Product specifications are Auxiliary power unit subject to change without notice. Relief valve 2000 psi 137.9 bar Part No.

  • Page 18: Manifold Component Specifications

    Solenoid valve, 2 position 3 way 6 to 8Ω 10V DC with diode (schematic items EF and EJ) Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 GS-3384 Part No. 82259...

  • Page 19: Gm 1.6L Engine

    Engine Operation Manual on your machine. Quantity Cold cranking ampere @ 0°F 1000A Reserve capacity @ 25A rate 200 minutes Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 82259 GS-3384 2 - 5...

  • Page 20: Ford Lrg-425 Efi Engine

    Engine Operator Handbook on your machine. Reserve capacity @ 25A rate 200 minutes Engine coolant Capacity 11.5 quarts 10.9 liters Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 6 GS-3384 Part No. 82259...

  • Page 21: C Duetz F3L 1011F Engine

    (including filter) 8 liters Continuous improvement of our products is a Oil viscosity requirements Genie policy. Product specifications are subject to change without notice. Units ship with 15W-40. Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operation Manual on your machine.

  • Page 22: C Duetz F3L 2011 Engine

    0.02 to 0.024 in 0.5 to 0.6 mm Lubrication system Continuous improvement of our products is a Oil pressure 20 to 43 psi Genie policy. Product specifications are 1.4 to 3 bar subject to change without notice. Oil capacity 8.5 quarts (including filter)

  • Page 23: Hydraulic Hose And Fitting Torque Specifications

    Your machine is equipped with Parker Seal-Lok ® The O-ring cannot be re-used if the fitting or fittings and hose ends. Genie specifications require hose end has been tightened beyond finger that fittings and hose ends be torqued to tight.
  • Page 24 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4 18.9 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 2 - 10 GS-3384 Part No. 82259...
  • Page 25 Indicates that an incorrect result has occurred · Wheels chocked after performing a series of steps. · All external AC power supply disconnected from the machine Part No. 82259 GS-3384 3 - 1...

  • Page 26: Pre-Delivery Preparation Report

    Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection. Make copies of the Maintenance Inspection Report to use for each inspection. Store completed forms for three years. 3 - 2 GS-3384 Part No. 82259...
  • Page 27 Genie UK 18340 NE 76th Street The Maltings, Wharf Road PO Box 97030 Grantham, Lincolnshire Redmond, WA 98073-9730 NG31- 6BH England (425) 881-1800 (44) 1476-584333 Copyright © 2002 by Genie Industries. Genie® is a registered trademark of Genie Industries. Rev B...
  • Page 28 Section 3 • Scheduled Maintenance Procedures September 2005 This page intentionally left blank. 3 - 4 GS-3384 Part No. 82259...

  • Page 29: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments Part No. 82259 GS-3384 3 - 5...
  • Page 30 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Comments 3 - 6 GS-3384 Part No. 82259...

  • Page 31: Checklist A Procedures

    Complete information to perform this procedure is Refer to the Operator's Manual on your machine. available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. Part No. 82259 GS-3384 3 - 7...

  • Page 32: Perform Engine Maintenance - Ford Models

    Operation Manual (Deutz part number 0297 9683) (Ford part number FPP 194-302). or the Deutz 2011 Operation Manual (Deutz part number 0297 9929). Ford LRG 425 Operator Handbook Genie part number 84792 Deutz 1011F Operation Manual Genie part number 52883...

  • Page 33: Check The Engine Coolant Level - Gm Models

    6 Inspect for puddles, dripping or residue on or around the following areas: 4 Disconnect the retaining clamp from the air · Engine tray—fittings, hoses, water pump · The underside of the drive chassis · Ground area under the machine Part No. 82259 GS-3384 3 - 9...

  • Page 34: Check The Battery - Gm Models

    3 Disconnect the battery retaining fasteners. 4 Remove the battery vent caps. 5 Check the battery acid level. If needed, replenish with distilled water to the bottom of each battery fill tube. Do not overfill. 3 - 10 GS-3384 Part No. 82259...

  • Page 35: Inspect The Radiator - Gm Models

    2 Insert a 6 inch / 15 cm screwdriver or rod into the engine tray lock hole, located near the engine tray roller wheels, to prevent the engine tray from moving. Part No. 82259 GS-3384 3 - 11...

  • Page 36: Check The Engine Fasteners - Gm Models

    6 Tighten all engine starter mounting fasteners. Torque to 16 to 19 ft-lbs / 22 to 26 Nm. 7 Tighten all fan retaining fasteners. Torque to 16 to 19 ft-lbs / 22 to 26 Nm. 3 - 12 GS-3384 Part No. 82259...

  • Page 37: Perform Engine Maintenance - Deutz Models

    Ford LRG425 Operator Handbook or the Deutz 2011 Operation Manual (Deutz part (Ford part number FPP 194-302). number 0297 9929). Ford LRG 425 Operator Handbook Genie part number 84792 Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual...

  • Page 38: Check The Alternator Belt - Gm Models

    2 Insert a 6 inch / 15 cm screwdriver or rod into the engine tray lock hole, located near the engine tray roller wheels, to prevent the engine tray from moving. 3 - 14 GS-3384 Part No. 82259...

  • Page 39: Check The Hydraulic Return Filter Condition Indicator (If Equipped)

    A-15 Check the Hydraulic Return Filter Perform Engine Maintenance - Condition Indicator (if equipped) Deutz 1011F Models Genie specifications require that this procedure be performed every 100 hours of operation. Engine specifications require that this procedure be performed every Maintaining the hydraulic return filter in good...

  • Page 40: Drain The Fuel Filter/ Water Separator - Deutz Models

    Drain the Fuel Filter/ Water container until fuel starts to come out. Separator - Deutz Models Immediately tighten the drain plug. Genie specifications require that this procedure be performed every 200 hours or monthly, whichever comes first. Proper maintenance of the fuel filter/water separator is essential for good engine performance.

  • Page 41: Perform Engine Maintenance - Ford Models

    Periodic replacement of the engine oil and filter is essential to good engine performance. Operating the machine with an improper oil level or Ford LRG 425 Operator Handbook Genie part number 84792 neglecting periodic oil and filter changes can damage engine components. A daily check of...
  • Page 42 12 Check the oil filter and oil pan drain plug for leaks. 13 Check the engine oil level dipstick. Add oil if needed. 14 Clean up any oil that may have spilled. Properly dispose of the oil and filter. 3 - 18 GS-3384 Part No. 82259...

  • Page 43: Checklist B Procedures

    1 Put on protective clothing and eye wear. 2 Be sure that the battery cable connections are free of corrosion. Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables. Part No. 82259 GS-3384 3 - 19...

  • Page 44: Inspect The Electrical Wiring

    11 Raise the platform and return the safety arm to · All wire harness connectors the stowed position. · Level sensor 12 Lower the platform to the stowed position and turn the machine off. 3 - 20 GS-3384 Part No. 82259...

  • Page 45: Perform Engine Maintenance - Deutz 1011F Models

    Operation Manual (Deutz part number 0297 9683). running. Remove the key to secure from operation. Deutz 1011F Operation Manual Bodily injury hazard. Beware of Genie part number 52883 hot engine components. Contact with hot engine components may cause severe burns.

  • Page 46: Inspect The Engine Air Filter - Ford And Deutz Models

    2 Insert a 6 inch / 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine Genie specifications require that tray from moving. this procedure be performed every...

  • Page 47: Check And Adjust The Engine Rpm

    ECM and can only be adjusted by re-programming the ECM. If rpm adjustment or service is required, please contact the Genie Industries Service Department OR your local Ford dealer. Tighten the low idle lock nut and repeat step 2.
  • Page 48 Skip to step 11 if the high idle rpm is correct. If the high idle rpm is not correct and the low idle was just calibrated, proceed to step 10. All other machines, open the engine tray. Proceed to step 8. 3 - 24 GS-3384 Part No. 82259...

  • Page 49: Confirm The Proper Brake Configuration

    3 Check each lug nut for proper torque. Refer to Section 2, Specifications. Models with air-filled tires: 4 Check pressure in each air-filled tire. Add air as necessary. Refer to Section 2, Specifications. Part No. 82259 GS-3384 3 - 25...

  • Page 50: Check The Oil Level In The Drive Hubs

    Refer to Section 2, Specifications. 4 Apply pipe thread sealant to the plug(s), and then install the plug(s) in the drive hub. 5 Repeat this procedure for each drive hub. 3 - 26 GS-3384 Part No. 82259...

  • Page 51: Test The Emergency Stop

    Result: The engine should shut off and no machine functions should operate. The red Emergency Stop button at the ground or platform controls will stop all machine operation without regard to the position of the key switch. Part No. 82259 GS-3384 3 - 27...

  • Page 52: Test The Fuel Select Operation - Ford And Gm Models

    3 Press high idle button again to return the engine to low idle. Result: The high idle indicator light should turn off and the engine should return to low idle. 4 Press the engine stop button. Result: The engine should stop. 3 - 28 GS-3384 Part No. 82259...

  • Page 53: Test The Drive Brakes

    5 Measure the distance between the test line and your machine reference point. Refer to Section 2, Specifications. The brakes must be able to hold the machine on any slope it is able to climb. Part No. 82259 GS-3384 3 - 29...

  • Page 54: Test The Drive Speed - Raised Position

    8 Continue at full speed and note the time when the machine reference point passes over the finish line. Refer to Section 2, Specifications. 3 - 30 GS-3384 Part No. 82259...

  • Page 55: Perform Hydraulic Oil Analysis

    4 Remove the filter housing using a wrench on the nut provided on the bottom of the housing. 5 Remove the filter element from the housing. Part No. 82259 GS-3384 3 - 31...
  • Page 56 8 Locate the high pressure hydraulic filter mounted next to the function manifold. 9 Remove the filter housing using a filter wrench. Genie requires that this procedure be performed every 250 hours or Bodily injury hazard. Spraying quarterly, whichever comes first.

  • Page 57: Replace The Engine Air Filter Element - Ford And Gm Models

    6 Clean the inside of the canister and the gasket with a damp cloth. 7 Install the new filter element. 8 Install the air filter canister end cap and the end cap retaining ring. Part No. 82259 GS-3384 3 - 33...

  • Page 58: Perform Engine Maintenance - Ford Models

    (Ford part number FPP 194-302). 6 Install the new filter element. Ford LRG 425 Operator Handbook 7 Install the air filter canister end cap and the end Genie part number 84792 cap retaining ring. 3 - 34 GS-3384 Part No. 82259...

  • Page 59: Replace The Fuel Filter - Gm Models

    2 Carefully lower the fuel pump mounting plate. fuel and hydraulic tank tray and tighten the 3 Turn the manual shutoff valves, located at the mounting fasteners. fuel tank, to the position. CLOSED Part No. 82259 GS-3384 3 - 35...

  • Page 60: Check The Specific Gravity Of The Engine Coolant - Gm Models

    2 Stop the engine. 3 Allow the engine to cool until the temperature of the coolant is below 140°F / 60°C. Burn hazard. Beware of hot coolant. Contact with hot coolant may cause severe burns. 3 - 36 GS-3384 Part No. 82259...

  • Page 61: C Checklist C Procedure

    Emergency Stop button to the on position at both the ground and platform controls. 10 Fully raise the platform. Release the joystick. Genie specifications require that this procedure be performed every Result: The engine should stop and an alarm 500 hours or six months,...

  • Page 62: C-3 Perform Engine Maintenance - Deutz Models

    Failure to perform this procedure can lead to poor engine performance and component damage. Deutz 1011F Operation Manual Perform this procedure with the Genie part number 52883 engine off. Deutz 2011 Operation Manual 1 Release the latches on the engine tray and fully...

  • Page 63: Replace The Hydraulic Tank Breather Cap - Models With Optional Hydraulic Oil

    (Ford part number FPP 194-302). conditions may require that the cap be inspected more often. Ford LRG 425 Operator Handbook 1 Remove and discard the hydraulic tank breather Genie part number 84792 cap. 2 Install and new cap onto the tank. Part No. 82259...

  • Page 64: Clean The Pcv Hoses And Fittings - Gm Models

    Bodily injury hazard. Allow any pressure to dissipate gradually before removing the radiator cap. 4 Open the drain valve on the radiator and allow the coolant to drain into a suitable container. See capacity specifications. 3 - 40 GS-3384 Part No. 82259...

  • Page 65: Replace The Lpg Filter - Gm Models

    12 Check the fluid level in the radiator and add fluid as needed. Install the radiator cap. Result: The fluid level should be visible in the top of the radiator. 13 Clean up any coolant that may have spilled during this procedure. Part No. 82259 GS-3384 3 - 41...

  • Page 66: Replace The Spark Plugs And Spark Plug Wires - Gm Models

    For accurate installation of the new spark plug wires, replace the spark plug wires one at a time following the routing of the original spark plug wires. 3 - 42 GS-3384 Part No. 82259...

  • Page 67: Checklist D Procedures

    Result: The measurement is inch / 8 mm or more. Proceed to step 3. Result: The measurement is less than inch / 8 mm. Replace both wear pads. Part No. 82259 GS-3384 3 - 43...

  • Page 68: Check The Free-Wheel Configuration

    Raise the machine and remove the blocks. Lower the machine. disengaged position Collision hazard. Failure to engage the drive hubs could result in death or serious injury and property damage. engaged position 3 - 44 GS-3384 Part No. 82259...

  • Page 69: Replace The Drive Hub Oil

    Apply pipe thread sealant to the plugs. Install the plugs. Refer to Section 2, Specifications. 5 Repeat steps 1 through 4 for all the other drive hubs. Part No. 82259 GS-3384 3 - 45...

  • Page 70: Calibrate The Platform Overload System (If Equipped)

    4 Remove the fuel filter/water separator with a filter wrench. Calibrate the Platform Overload System (if equipped) Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. On machines with platform overload systems, proper calibration is essential to safe machine operation.
  • Page 71 Refer to the chart below. off position at the ground controls. 14 Pull out the red Emergency Stop button to the GS-3384 1878 kg on position at the ground controls. Wait 3 seconds and start the engine.
  • Page 72 20 Return the safety arm to the stowed position. Lower the platform to the stowed position. After returning the safety arm to the stowed position, use the auxiliary down function to lower the platform. 3 - 48 GS-3384 Part No. 82259...
  • Page 73 Do not over tighten. Secure the weight to the platform. Refer to the chart below. GS-3384 1135 kg 22 Raise the platform to approximately 6 m. 23 Release the safety arm latch, lift the safety arm and rotate to a vertical position.
  • Page 74 38 Push in the red Emergency Stop button to the off position at the ground controls. 39 Pull out the red Emergency Stop button to the on position at the ground controls. For more information on programming, refer to Section 4, Repair. 3 - 50 GS-3384 Part No. 82259...
  • Page 75 64 Raise the platform approximately 1 m. 65 Return the safety arm to the stowed position. 66 Repeat this procedure beginning with step 59. Part No. 82259 GS-3384 3 - 51...
  • Page 76 DOWN LIMIT SWITCH OUT OF ADJUSTMENT RAISE THE DOWN LIMIT SWITCH TOO MUCH WEIGHT IN PLATFORM PUT CORRECT RATED LOAD IN PLATFORM TURN THE PRESSURE SWITCH NUT 1/4 OVERLOAD SYSTEM NOT ADJUSTED TURN INTO THE HYDRAULIC LINE -OR- PROPERLY REPEAT CALIBRATION PROCEDURE 3 - 52 GS-3384 Part No. 82259...

  • Page 77: Replace The Hydraulic Tank Return Filter

    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. Part No. 82259 GS-3384 3 - 53...

  • Page 78: Perform Engine Maintenance - Deutz Models

    Deutz 1011F Operation Manual (Deutz part number 0297 9683) or the Deutz 2011 Operation Manual (Deutz part number 0297 9929). Deutz 1011F Operation Manual Genie part number 52883 Deutz 2011 Operation Manual Genie part number 84794...

  • Page 79: B Checklist E Procedure

    1 Turn the key switch to ground controls and pull out the red Emergency Stop buttons to the on position at both the ground and platform controls. Part No. 82259 GS-3384 3 - 55...
  • Page 80 22 Install the hydraulic tank strap. 11 Tag, disconnect and plug the two suction hoses 23 Install the two suction hoses. that are attached to the hydraulic tank shutoff valves or tank. 3 - 56 GS-3384 Part No. 82259...

  • Page 81: Change The Fuel Hoses - Gm Models

    Emergency Stop buttons to the on position at both the ground and platform controls. 2 Start the engine. 3 Raise the platform approximately 18 feet / 5.5 m from the ground. Part No. 82259 GS-3384 3 - 57...
  • Page 82 12 Remove the retaining fasteners from the fuel pump mounting plate located under the fuel and hydraulic tank tray. hose from fuel tank to filter hose from filter to fuel pump high pressure hose from fuel pump to engine 3 - 58 GS-3384 Part No. 82259...

  • Page 83: Perform Engine Maintenance - Deutz 1011F Models

    Repair the leak Deutz 1011F Operation Manual immediately. Genie part number 52883 21 Install the access plate behind the fuel and hydraulic tank tray. 22 Raise the platform and return the safety arm to the stowed position.

  • Page 84: Perform Engine Maintenance - Ford Models

    Operation Manual (Deutz part number 0297 9683) (Ford part number FPP 194-302). or the Deutz 2011 Operation Manual (Deutz part number 0297 9929). Ford LRG 425 Operator Handbook Genie part number 84792 Deutz 1011F Operation Manual Genie part number 52883...
  • Page 85 Indicates that a specific result is expected after · All external AC power supply disconnected performing a series of steps. from the machine Indicates that an incorrect result has occurred after performing a series of steps. Part No. 82259 GS-3384 4 - 1...

  • Page 86: Platform Controls

    ECM is in the programming mode (PS showing in the diagnostic display window). For further information or assistance, consult the Genie Industries Service Department. Platform controls after serial number GS8403-40212 alarm H1 function enable/high speed select...

  • Page 87: Circuit Boards

    Depress the locking tab to disconnect the wire harness from the circuit board. 7 Remove the platform controls circuit board retaining fasteners. 8 Remove the platform controls circuit board from the platform control box lid. Part No. 82259 GS-3384 4 - 3...
  • Page 88 10 Turn the key switch to the off position. wire. 11 Close the lid and install the fasteners. Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 4 - 4 GS-3384 Part No. 82259...

  • Page 89: Controller Adjustments (Before Serial Number Gs8403-40213)

    For further information or assistance, consult the Refer to the appropriate Genie service manual for code descriptions. Genie Industries Service Department. HOUR METER Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting...
  • Page 90 Drive Speed - Raised Position. ® Stop ® STOP Stop AUTO LEVEL STOP steering rocker switch SW6 horn button BN5 platform extend/retract enable BN16 OR outrigger enable button BN16 4 - 6 GS-3384 Part No. 82259...
  • Page 91 8 Turn the key switch to the off position to save the settings. ® STOP Stop AUTO LEVEL STOP steering rocker switch SW6 function enable/high speed select button BN12 horn button BN5 platform extend/retract enable BN16 OR outrigger enable button BN16 Part No. 82259 GS-3384 4 - 7...
  • Page 92 8 Turn the key switch to the off position to save the settings. ® STOP Stop AUTO LEVEL STOP steering rocker switch SW6 function enable/low speed select button BN13 horn button BN5 platform extend/retract enable BN16 OR outrigger enable button BN16 4 - 8 GS-3384 Part No. 82259...
  • Page 93 3 to 5 points less STOP than the Platform Lowering Speed percentage. steering rocker switch SW6 platform up/down select switch TS20 horn button BN5 platform extend/retract enable BN16 OR outrigger enable button BN16 Part No. 82259 GS-3384 4 - 9...
  • Page 94 STOP Stop AUTO LEVEL STOP steering rocker switch SW6 horn button BN5 machine on incline button BN6 OR machine on incline/LF outrigger button BN17 platform extend/retract enable BN16 OR outrigger enable button BN16 4 - 10 GS-3384 Part No. 82259...

  • Page 95: Software Configuration (Before Serial Number Gs8403-40213)

    DIP switch SW25 circuit board U3 joystick controller JC1 5 Apply dielectric grease to the DIP switch after setting the configuration. 6 Close the lid and install the platform control box lid fasteners. Part No. 82259 GS-3384 4 - 11...
  • Page 96 Installed on all machines. SYSTEM 20 AMP Refer to the appropriate Motion Beacon: The motion beacon option Genie service manual for code descriptions. flashes only when operating a function. HOUR METER Overload: This cuts out all functions when the pressure sensor is overloaded. The Emergency Stop button must be cycled before any function can be resumed.
  • Page 97 10011100 • • • • 10101101 • • • • 01011111 • • • • 00111111 • • • • • 00101111 • • • • • 10101111 Continued to the next page Part No. 82259 GS-3384 4 - 13...
  • Page 98 • 00110100 10110100 • • • • • • • • • • • • • 00110110 10110110 • • • • • • • • • • • • • 00111001 10110111 4 - 14 GS-3384 Part No. 82259...

  • Page 99: Platform Components

    Component damage hazard. The clear of the safety arm when platform controls wiring can be lowering the platform. damaged if it is kinked or pinched. 14 Remove the AC power to platform outlet bracket mounting fasteners. Part No. 82259 GS-3384 4 - 15...
  • Page 100 Component damage hazard. The secured to the platform. platform railings can be damaged if used to lift the platform. Do not attach the lifting straps to the platform railings. 4 - 16 GS-3384 Part No. 82259...

  • Page 101: Platform Extension Deck

    4 At the platform extension deck to be removed, position a fork lift with the forks even with the bottom of the platform extension deck. 5 Lift the platform extension deck lock handle. Part No. 82259 GS-3384 4 - 17...

  • Page 102: Scissor Components

    17 Number 1 center pivot pins Number 1 inner arm 18 Chassis centering link Lift cylinder barrel-end pivot pin 19 Number 1 pivot pins (steer end) 10 Number 1 pivot pins (non-steer end) 4 - 18 GS-3384 Part No. 82259...

  • Page 103: Scissor Assembly, Gs-3384

    SCISSOR COMPONENTS 5 Use a soft metal drift to remove the lift cylinder rod-end pivot pin (index #12). Lower the rod Scissor Assembly , GS-3384 end of the lift cylinder down onto the number 2 inner arm (index #6). How to Disassemble the Crushing hazard.
  • Page 104 24 Place a 6 x 6 x 32 inch / 15 x 15 x 80 cm long the machine. block across both sides of the chassis under the barrel end of the lift cylinder. 4 - 20 GS-3384 Part No. 82259...
  • Page 105 33 Remove the strap installed in step 19. 42 Use a slide hammer to remove both number 1 34 Support the cable tray with an overhead crane. pivot pins (index #10) from the non-steer end of the machine. Part No. 82259 GS-3384 4 - 21...
  • Page 106 #16) at the non-steer end of the machine. Do not apply any lifting pressure. 49 Remove the pin retaining fasteners from both chassis centering link pivot pins (index #18) at the number 1 inner arm. 4 - 22 GS-3384 Part No. 82259...
  • Page 107 Attach the lifting strap to the end of the scissor arm that has the casting pointing upwards. 3 Raise the scissor arms with the overhead cranes approximately 12 inches / 30 cm. Part No. 82259 GS-3384 4 - 23...

  • Page 108: Wear Pads

    Rest the 14 Attach the platform centering links to the centering links on the scissor arms. platform and install the platform centering link pivot pins and the pin retaining fasteners. 4 - 24 GS-3384 Part No. 82259...
  • Page 109 Part No. 82259 GS-3384 4 - 25...

  • Page 110: Lift Cylinder

    Refer to Section Two, Hydraulic Hose and Fitting Torque Specifications. 1 Start the engine from the ground controls and raise the platform approximately 18 feet / 5.5 m from the ground. 4 - 26 GS-3384 Part No. 82259...
  • Page 111 7 Attach a lifting strap from a second overhead crane or similar lifting device to the lifting eye at the barrel end of the lift cylinder for support. Part No. 82259 GS-3384 4 - 27...

  • Page 112: Rpm Adjustment

    2 Insert a 6 inch / 15 cm screwdriver or rod into the engine tray lock hole located near the engine tray roller wheels to prevent the engine tray from moving. 4 - 28 GS-3384 Part No. 82259...
  • Page 113 14 Raise the engine slightly with the lifting jack to Liquid Petroleum Gas (LPG). take the pressure off the rubber vibration Contact with LPG may cause isolators under the bell housing. Remove the severe burns. rubber vibration isolators. Part No. 82259 GS-3384 4 - 29...
  • Page 114 Component damage hazard. Hoses can be damaged if they are kinked or pinched. 9 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. 4 - 30 GS-3384 Part No. 82259...
  • Page 115 / 11 mm gap 5 Apply Loctite ® removable thread sealant to the pump coupler set screw. Torque the set screw to 61 ft-lbs / 83 Nm. Flex plate bolt torque sequence Part No. 82259 GS-3384 4 - 31...
  • Page 116 8 Ford models: Install the air cleaner mount bracket onto the bell housing. Install the fasteners and torque to 28 ft-lbs / 38 Nm. Bell housing bolt torque sequence Bell housing bolt torque sequence (Ford models) (Deutz models) 4 - 32 GS-3384 Part No. 82259...

  • Page 117: Oil Temperature And Oil Pressure Switches - Deutz Models

    Torque 8-10 ft-lbs tray from moving. 11-14 Nm Hex size inches Oil pressure switch point 7 psi 0.48 bar Part No. 82259 GS-3384 4 - 33...

  • Page 118: Coolant Temperature And Oil Pressure Switches - Ford Models

    Oil pressure switch specifications tray from moving. 3 Locate the oil pressure or coolant temperature Torque 8-10 ft-lbs 11-14 Nm switch. Hex size inches Oil pressure switch point 8 psi 0.55 bar 4 - 34 GS-3384 Part No. 82259...

  • Page 119: Coolant Temperature And Oil Pressure Switches - Gm Models

    Oil pressure switch specifications Burn hazard. Contact with hot engine fluids or components may Torque 22 ft-lbs cause severe burns. 30 Nm Hex size inches Oil pressure switch point 8 psi 0.55 bar Part No. 82259 GS-3384 4 - 35...

  • Page 120: Ground Controls

    · Platform lower speed · Steer speed · Platform settling speed For further information or assistance, consult the Genie Industries Service Department. Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than...
  • Page 121 11 Check the stowed drive speed of the machine. Emergency Stop button to the on position at the Refer to the Maintenance procedure B-15, Test ground controls. the Drive Speed - Stowed Position. Part No. 82259 GS-3384 4 - 37...
  • Page 122 9 Press the lift function enable button. Refer to the Maintenance procedure B-15, Test the Drive Speed - Stowed Position. Result: is showing in the diagnostic TUNE SPEEDS display window. The ECM is now in programming mode. 4 - 38 GS-3384 Part No. 82259...
  • Page 123 3 Turn the key switch to ground control. always be within specifications. 9 Press the lift function enable button. 10 Push in the red Emergency Stop button to the off position at the ground controls. Part No. 82259 GS-3384 4 - 39...
  • Page 124 9 Press the lift function enable button. Result: is showing in the diagnostic TUNE SPEEDS display window. The ECM is now in programming mode. 4 - 40 GS-3384 Part No. 82259...
  • Page 125 Pull out the red Emergency Stop button to the on position at the ground controls. Result: is showing in the diagnostic TUNE SPEEDS display window. The ECM is now in programming mode. Part No. 82259 GS-3384 4 - 41...
  • Page 126 9 Press the lift function enable button. Refer to the Maintenance procedure B-16, Test the Drive Speed - Raised Position. Result: is showing in the diagnostic TUNE SPEEDS display window. The ECM is now in programming mode. 4 - 42 GS-3384 Part No. 82259...
  • Page 127 10 Push in the red Emergency Stop button to the diagnostic display window. off position at the ground controls. 7 Press the lift function enable button. 11 Check the lift speed of the machine. Refer to Section 2, Specifications. Part No. 82259 GS-3384 4 - 43...
  • Page 128 MAX DESCENT SPEED 10 Push in the red Emergency Stop button to the diagnostic display window. off position at the ground controls. 11 Check the lower speed of the machine. Refer to Section 2, Specifications. 4 - 44 GS-3384 Part No. 82259...
  • Page 129 3 to 5 points less than the Platform Lowering Speed percentage. 9 Press the lift function enable button. 10 Push in the red Emergency Stop button to the off position at the ground controls. Part No. 82259 GS-3384 4 - 45...
  • Page 130 6 Use the yellow platform down arrow to scroll to 10 Push in the red Emergency Stop button to the steering speed. off position at the ground controls. Result: is showing in the STEERING SPEED diagnostic display window. 4 - 46 GS-3384 Part No. 82259...

  • Page 131: Software Configuration (After Serial Number Gs8403-40212)

    Emergency Stop buttons are in the on position. diagnostic display blue platform up button lift function enable button yellow platform down button Part No. 82259 GS-3384 4 - 47...
  • Page 132 13 Press the lift function enable button. Result: is showing in the SELECT OPTIONS diagnostic display window. 14 Push in the red Emergency Stop button to the off position at the ground controls. 4 - 48 GS-3384 Part No. 82259...
  • Page 133 OR use diagnostic display window. The ECM is now in the yellow platform down arrow to scroll to programming mode. motion beacons. Result: is showing in the MOTION BEACONS diagnostic display window. Part No. 82259 GS-3384 4 - 49...
  • Page 134 SIM OPERATION ON diagnostic display window. Press the lift function enable button to deactivate the sim operation option. For CE models, the sim operation option should be deactivated or in position. 4 - 50 GS-3384 Part No. 82259...

  • Page 135: Level Sensor - Models Without Outriggers (Before Serial Number 40077)

    6 Place a 1.97 x 10 x 10 inch / 5 x 25 x 25 cm 14 Remove the level sensor retaining fasteners. thick steel block under both wheels at the steer Remove the level sensor from the machine. end of the machine. Part No. 82259 GS-3384 4 - 51...
  • Page 136 28 Lower the machine onto the blocks. Level sensor - models without outriggers chassis level sensor "X" indicator "Y" indicator 4 - 52 GS-3384 Part No. 82259...
  • Page 137 Models with flotation tires: Place a controls side of the machine. 3.15 x 10 x 10 inch / 8 x 25 x 25 cm thick steel block under both wheels at the ground controls side of the machine. Part No. 82259 GS-3384 4 - 53...

  • Page 138: Level Sensor - Models Without Outriggers (After Serial Number 40076)

    If you are not installing a new level sensor, proceed to step 10. 3 Push in the red Emergency Stop button to the off position at the platform controls. 4 Remove the ground control panel retaining fasteners and open the panel. 4 - 54 GS-3384 Part No. 82259...
  • Page 139 180 beeps per minute. Turn the level sensor adjusting nuts just until the level sensor alarm does not sound. Level sensor - models without outriggers chassis level sensor "X" indicator "Y" indicator Part No. 82259 GS-3384 4 - 55...

  • Page 140: Level Sensor - Models With Outriggers

    3 Remove the ground control panel retaining 29 Raise the machine slightly. fasteners and open the panel. 30 Remove the blocks from under both wheels. 31 Lower the machine and remove the jack. 4 - 56 GS-3384 Part No. 82259...
  • Page 141 Failure to install the tilt level sensor as instructed could result in the machine tipping over causing death or serious injury. MODELS WITH OUTRIGGERS Level sensor - models without outriggers chassis level sensor "Y" indicator "X" indicator Part No. 82259 GS-3384 4 - 57...
  • Page 142 3 seconds or until a beep is heard. 26 Push in the red Emergency Stop button to the off position at the platform controls. 4 - 58 GS-3384 Part No. 82259...
  • Page 143 41 Lower the platform to the stowed position. 42 Raise the machine slightly. 43 Remove the blocks from under both wheels. 44 Lower the machine and remove the jack. Part No. 82259 GS-3384 4 - 59...
  • Page 144 62 Lower the machine and remove the jack. 52 Remove the blocks from under both wheels. 63 Turn the key switch to the off position. 53 Lower the machine and remove the jack. 4 - 60 GS-3384 Part No. 82259...

  • Page 145: Engine Fault Codes - Ford Models

    1.2 seconds and then blinks 1 time. That would indicate code 51. The ECM is able to store up to six individual fault codes. There will be a 2.4 second pause between codes. Part No. 82259 GS-3384 4 - 61...

  • Page 146: Hydraulic Pumps

    Result: If the pressure fails to reach 3500 psi /241 bar, the pump or pump coupling is bad and will need to be serviced or replaced. 6 Remove the pressure gauge and connect the hydraulic hose. 4 - 62 GS-3384 Part No. 82259...
  • Page 147 Refer to Section 2, Specifications. 3 Release the latches on the engine tray and fully Part No. 82259 GS-3384 4 - 63...

  • Page 148: Drive Pump

    Sundstrand-Sauer service center. Contact the gradually. Do not allow oil to Genie Industries Service Department to locate squirt or spray. your local authorized service center. 4 Support the drive pump with a suitable lifting...

  • Page 149: Manifolds

    Move the fuel select toggle switch at the ground controls to the gasoline position. Deutz models: Release the manual fuel shut-off lever. 6 Start the engine from the ground controls and check for hydraulic leaks. Part No. 82259 GS-3384 4 - 65...

  • Page 150: Function Manifold Components - Models With Outriggers

    0.1 gpm / 0.38 L/min ......AJ ..Bleeds off proportional valve to tank ..........20 ft-lbs / 27.1 Nm DO3 valve, 3 position 4 way ..... AK ..Outrigger up/down ....... 30-35 in-lbs / 3-4 Nm 4 - 66 GS-3384 Part No. 82259...
  • Page 151 September 2005 Section 4 • Repair Procedures REV D MANIFOLDS Part No. 82259 GS-3384 4 - 67...

  • Page 152: Function Manifold Components - Models Without Outriggers

    Orifice - Plug, 0.150 inch / 3.8 mm ... AI ... Platform down circuit Flow regulator, 0.1 gpm / 0.38 L/min ......AJ ..Bleeds off proportional valve to tank ..........20 ft-lbs / 27.1 Nm 4 - 68 GS-3384 Part No. 82259...
  • Page 153 September 2005 Section 4 • Repair Procedures REV D MANIFOLDS Part No. 82259 GS-3384 4 - 69...

  • Page 154: Drive Manifold Components (Before Serial Number Gs8404-40297)

    ..........25 ft-lbs / 33.9 Nm Flow divider/combiner valve ....BM ..Balances flow from flow divider/combiner valves BJ and BK in forward and reverse ......... 25 ft-lbs / 33.9 Nm 4 - 70 GS-3384 Part No. 82259...
  • Page 155 September 2005 Section 4 • Repair Procedures REV D MANIFOLDS Part No. 82259 GS-3384 4 - 71...

  • Page 156: Drive Manifold Components (After Serial Number Gs8404-40296)

    Orifice - Plug, 0.090 inch / 2.3 mm ..EM ..Balances flow from flow divider/ combiner (item EA) to flow divider/ combiner valves ED and EL ......25 ft-lbs / 34 Nm Diagnostic nipple ....... EN ..Testing "P1" pressure port 4 - 72 GS-3384 Part No. 82259...
  • Page 157 September 2005 Section 4 • Repair Procedures REV D MANIFOLDS Part No. 82259 GS-3384 4 - 73...

  • Page 158: Valve Adjustments - Function Manifold

    5 Determine the test weight for your machine. to increase the pressure or counterclockwise to Refer to the specifications below. decrease the pressure. Install the relief valve cap. Rated work load at full height, maximum GS-3384 2500 lbs 1135 kg 4 - 74 GS-3384 Part No. 82259...
  • Page 159 (item F or AB) on the specifications below. function manifold. Additional test weight 2 Start the engine from the platform controls. GS-3384 500 lbs 3 Press and hold the function enable switch and 227 kg hold the steer thumb rocker switch in the RIGHT direction.

  • Page 160: Valve Adjustments - Drive Manifold

    5 Adjust the internal hex socket. Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure. Install the relief valve cap. 6 Repeat steps 2 through 3 to confirm the relief valve pressure. 4 - 76 GS-3384 Part No. 82259...
  • Page 161 September 2005 Section 4 • Repair Procedures REV D MANIFOLDS This page intentionally left blank. Part No. 82259 GS-3384 4 - 77...

  • Page 162: Generator Manifold Components

    Flow regulator, 4.3 gpm / 16.3 L/min ..AM ..Generator speed ........20 ft-lbs / 27 Nm Relief valve, 3000 psi / 206.8 bar ... AN ..Generator circuit ........20 ft-lbs / 27 Nm 4 - 78 GS-3384 Part No. 82259...

  • Page 163: Valve Adjustments - Generator Manifold

    1 Disconnect all electrical tools from the machine. generator AC voltage. 2 Start the engine from the platform controls. 3 Press the generator select switch. Result: The generator should activate and the engine should go to high rpm. Part No. 82259 GS-3384 4 - 79...

  • Page 164: Valve Coils

    Solenoid valve, 2 position 2 way 9 to 11Ω coil. 12V DC with diode (schematic item DG) Solenoid valve, 2 position 3 way 6 to 8Ω 10V DC with diode (schematic items EF and EJ) 4 - 80 GS-3384 Part No. 82259...
  • Page 165 September 2005 Section 4 • Repair Procedures REV D MANIFOLDS How to Test a Coil Diode Genie incorporates spike suppressing diodes in all COIL of its valve coils. Properly functioning coil diodes MULTI METER protect the electrical circuit by suppressing voltage spikes.

  • Page 166: Fuel And Hydraulic Tanks

    Component damage hazard. The fuel tank is plastic and may become damaged if allowed to fall. Clean the fuel tank and inspect for cracks and other damage before installing. 4 - 82 GS-3384 Part No. 82259...

  • Page 167: Hydraulic Tank

    Be sure that the safety arm is machine to inform personnel of the locked in the vertical position. condition. Part No. 82259 GS-3384 4 - 83...
  • Page 168 See 6-2, How to Prime the Pump. Always use pipe thread sealant when installing the drain plug and strainers. 4 - 84 GS-3384 Part No. 82259...

  • Page 169: Steer Axle Components

    Drive motor mounting bolts, lubricated 56 ft-lbs burn skin. Loosen hydraulic 76 Nm connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 82259 GS-3384 4 - 85...
  • Page 170 Drive motor mounting bolts, lubricated 56 ft-lbs 2 inches / 5 cm. Place blocks under the chassis 76 Nm for support. Crushing hazard. The chassis will fall if it is not properly supported. 4 - 86 GS-3384 Part No. 82259...

  • Page 171: Steer Cylinder

    Place a rod through the pin and twist to remove the pin. Note the location and the amount of the spacers at the barrel end of the steer cylinder. 4 Remove the steer cylinder from the machine. Part No. 82259 GS-3384 4 - 87...

  • Page 172: Non-Steer Axle Components

    Refer to Section Two, Hydraulic Torque specifications Hose and Fitting Torque Specifications. Drive motor mounting bolts, dry 75 ft-lbs 102 Nm 1 Block the steer wheels. Drive motor mounting bolts, lubricated 56 ft-lbs 76 Nm 4 - 88 GS-3384 Part No. 82259...

  • Page 173: Drive Hub

    2 inches / 5 cm. Place blocks under the chassis for support. Crushing hazard. The chassis will fall if it is not properly supported. 6 Remove the wheel lug nuts. Remove the tire and wheel assembly. Part No. 82259 GS-3384 4 - 89...

  • Page 174: Outrigger Components

    Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin. Loosen hydraulic connections very slowly to allow the oil pressure to dissipate valve coil gradually. Do not allow oil to squirt outrigger cylinder or spray. 4 - 90 GS-3384 Part No. 82259...
  • Page 175 · The red Emergency Stop button in the off gradually. Do not allow oil to position at both ground and platform controls squirt or spray. · Wheels chocked · All external AC power supply disconnected from the machine Part No. 82259 GS-3384 5 - 1...
  • Page 176 The codes listed in the Fault Code Chart describe malfunctions and can aid in troubleshooting the machine by pinpointing the Return to Inspect Perform service and test repair area or component affected. problem solved 5 - 2 GS-3384 Part No. 82259...
  • Page 177 Down coil (Y7) fault. disconnected from coil. wire connection. High speed bypass coil Malfunctioning coil OR wire Troubleshoot coil OR inspect Flash (Y49, Y49A) fault disconnected from coil. wire connection. Continued on next page Part No. 82259 GS-3384 5 - 3...
  • Page 178 OR check the wiring at the ECM OR replace the oil temperature switch. Solid Low ECM voltage. Battery discharged. Charge battery. Consult Genie Industries Flash Low RPM Engine idle RPM too low. Service Department. Consult Genie Industries Flash High RPM Engine RPM too high.
  • Page 179 START SW FAULT Left front outrigger enable Troubleshoot button OR replace printed button fault at platform Outriggers disabled. LEFT FRONT circuit board at platform controls. controls. OUTRIG SW FLT Part No. 82259 GS-3384 5 - 5...
  • Page 180 Forward 2 coil (Y6A) fault. Troubleshoot coil OR wiring. FORWARD 2 COIL elevated. FAULT Drives slow or not at all when Reverse 2 coil (Y5A) fault. Troubleshoot coil OR wiring. REVERSE 2 COIL elevated. FAULT 5 - 6 GS-3384 Part No. 82259...
  • Page 181 ECM OR replace the oil temperature switch. Low ECM voltage. System shutdown. Charge battery. LOW ECU VOLTAGE Consult Genie Industries Service Low RPM. Engine idle RPM too low. LOW ENGINE Department. Consult Genie Industries Service High RPM.
  • Page 182 HO2 sensor to the connections OR HO2 sensor is bad. ECM to ground OR replace HO2 sensor. 5 - 8 GS-3384 Part No. 82259...
  • Page 183 Check battery and/or alternator condition Battery supply voltage to the ECM is 18V DC OR check for shorted wires or poor System voltage high. or more. terminal connections from the battery to the ECM. Part No. 82259 GS-3384 5 - 9...
  • Page 184 Engine wire harness may have an intermittent Repair short in engine wire harness OR Adaptive Learn Low short to 5V DC or 12V DC OR fuel system test and repair the fuel system (LPG) components may be faulty. components. 5 - 10 GS-3384 Part No. 82259...
  • Page 185 OR there is a in place and secure OR repair wiring Camshaft Sensor Loss poor system ground connection OR sensor is and/or connections to sensor OR replace faulty. sensor. Continued on next page Part No. 82259 GS-3384 5 - 11...
  • Page 186 The MegaJector detects voltage less than 9.5 MegaJector voltage ECM and MegaJector OR replace battery volts for 5 seconds anytime the engine is supply low OR repair charging system OR replace cranking or running. the MegaJector. 5 - 12 GS-3384 Part No. 82259...
  • Page 187 #2 OR replace ignition coil shorted OR ignition coil #2 is faulty. If this fault appears on your machine, FPP1 High Voltage Not used. contact Genie Industries Service Department. If this fault appears on your machine, FPP1 Low Voltage Not used.
  • Page 188 Locate and repair any engine harness Loose wire connections to ECM OR ECM is RTI 3 Loss wiring damage or shorts to ECM to be faulty.S sure they are secure OR replace ECM. 5 - 14 GS-3384 Part No. 82259...
  • Page 189 Be sure that all necessary tools and test equipment are available and ready for use. Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Inspect Perform service repair and test problem solved Part No. 82259 GS-3384 6 - 1...

  • Page 190: Electronic Control Module Layout (Before Serial Number Gs8403-40213)

    Electronic Control Module Layout (before serial number GS8403-40213) REV A Platform controls Engine Pump Down limit switch Up limit switch To outriggers Electronic Control Module Level sensor Function manifold Drive manifold Horn Ground controls 6 - 2 GS-3384 Part No. 82259...
  • Page 191 18 pin connector (J3 and J4) Proportional coil (-) Y9 Diagnostic display G8 Plug Diagnostic display G8 Plug Plug Plug Emergency Stop relay CR41 terminal 87 Plug 36 pin connector (J1 and J2) Electronic Control Module Part No. 82259 GS-3384 6 - 3...

  • Page 192: Electronic Control Module Layout (After Serial Number Gs8403-40212)

    Platform controls Engine Flashing beacons Pump To outriggers Up limit switch Down limit To platform overload switch (CE models) Electronic Control Module Level sensor Oscillate manifold Drive manifold Horn Function manifold Ground controls 6 - 4 GS-3384 Part No. 82259...
  • Page 193 Auxiliary down relay CR23 Engine oil pressure SW2 terminal 87 (output) (input) Flashing beacons FS1 Engine water temp SW1 OR (output) oil temp SW3 (input) ECM power (input) Plug Fuel coil (GS68)(output) Plug Electronic Control Module Part No. 82259 GS-3384 6 - 5...

  • Page 194: Ford Engine Relay Layout

    September 2005 Ford Engine Relay Layout REV A F5-15A Power F4-15A F3-20A Relay F2-5A F1-30A Starter Fuel Pump Relay Relay Note: For detailed wire color information, refer to the Ford engine wiring harness diagrams. 6 - 6 GS-3384 Part No. 82259...

  • Page 195: Wiring Diagram - Platform Control Box (Before Serial Number Gs8403-40213)

    PLATFORM UP/DOWN BN12 BN13 TOGGLE SWITCH (MODELS WITHOUT OUTRIGGERS) COIL ALARM FUNCTION FUNCTION ENABLE/ ENABLE/ CORD TS21 PLATFORM UP/DOWN / OUTRIGGER UP/DOWN HIGH SPEED LOW SPEED ASSEMBLY TOGGLE SWITCH (MODELS WITH OUTRIGGERS) BUTTON BUTTON Part No. 82259 GS-3384 6 - 7...

  • Page 196: Wiring Diagram - Platform Control Box (After Serial Number Gs8403-40212)

    COIL CORD ASSEMBLY ALARM EMERGENCY STOP JOYSTICK CONTROLLER PLATFORM CONTROLS CIRCUIT BOARD WH/BL TS20 TS21 TS20 PLATFORM UP/DOWN TOGGLE SWITCH (MODELS WITHOUT OUTRIGGERS) TS21 PLATFORM UP/DOWN / OUTRIGGER UP/DOWN TOGGLE SWITCH (MODELS WITH OUTRIGGERS) 6 - 8 GS-3384 Part No. 82259...

  • Page 197: Electrical Schematics Abbreviation And Wire Color Legends

    1. Wires are labeled with Ford circuit number, color, and wire gauge. I< IU\\_g Example: 74GY/LB18 means circuit 74, grey wire with light blue stripe, G8 < GXYdU \eU 18 gauge wire G8 ; GXYdU \QS[ G8B4 GXYdUBUT 2. Internal splices are not shown. Part No. 82259 GS-3384 6 - 9...

  • Page 198: Electrical Symbols Legend

    WH/BK Spark plug STEER LEFT/ RIGHT FUNCTION ENABLE Toggle switch HALL EFFECT Diode GENERATOR JOYSTICK CONTROLLER Solenoid FUNCTION ENABLE STEER N.C. N.O. LEFT/ RIGHT Drive pump EDC Limit switch Joystick 12V DC Battery 6 - 10 GS-3384 Part No. 82259...

  • Page 199: Wiring Harness - Gm 1.6L

    CONNECTOR BK/RD WH/BL TO ALTERNATOR (ALT. TACH WIRE) WH/BK TO OIL PRESSURE SWITCH WH/BK CRANK SENSOR RD/WH BLACK CONNECTOR 23 PIN CONNECTOR MAP SENSOR CONNECTOR COOLANT TEMPERATURE SENSOR CONNECTOR AIR TEMPERATURE SENSOR CONNECTOR Part No. 82259 GS-3384 6 - 11...

  • Page 200: (Before Serial Number Gs8404-40302)

    RS 485 - 669 DG-W 18 669 DG-W 18 RS 232 TX 458 O-BK 18 458 O-BK 18 RS 232 RX TRIM VALVE 77 DB-Y 18 361A R 16 361A R 16 WPTWR2_GY E1280B 6 - 12 GS-3384 Part No. 82259...
  • Page 201 20 RS 485+ 461 O 18 461 O 18 21 RS 485- 669 DG-W 18 669 DG-W 18 11 RS 232+ 458 O-BK 18 458 O-BK 18 3 RS 232- 361A R 16 E1280B Part No. 82259 GS-3384 6 - 13...

  • Page 202: Wiring Harness - Ford Lrg-425 Efi (After Serial Number Gs8404-40301)

    RS 485 - 669 DG-W 18 669 DG-W 18 RS 232 TX 458 O-BK 18 458 O-BK 18 RS 232 RX TRIM VALVE 77 DB-Y 18 361A R 16 361A R 16 WPTWR2_GY E1429B 6 - 14 GS-3384 Part No. 82259...
  • Page 203 18 RS 232- 570 BK-W 16 PLUG (GROUND) 361A R 16 PLUG (RELAY POWER) 459 O-LG 18 361A R 16 PLUG (CAN -) MEGAJECTOR 662 DG-P 18 PLUG (CAN +) MTRTWR4 MTRSHD4 E1429B Part No. 82259 GS-3384 6 - 15...

  • Page 204: (Before Serial Number 40044)

    ELECTRONIC CONTROL MODULE POWER TO ENGINE ECM LOCKOUT TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN FUSE LINK STARTER - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7147 6 - 16 GS-3384 Part No. 82259...
  • Page 205 PLAT PLATFORM OVERLOAD DOWN DIAGNOSTIC LIMIT PRESSURE DISPLAY SWITCH SWITCH (OPTION) ELECTRONIC CONTROL MODULE 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7147 Part No. 82259 GS-3384 6 - 17...
  • Page 206 PIN2 LIFT ENABLE LOW BN13 PIN4 DOWN PIN3 PLATFORM & OUTRIGGER POUT1 PIN4 UP/DOWN TS21 DOWN ALARM POUT1 PIN11 ALARM PIN11 PLATFORM CONTROLS PLATFORM CONTROLS (GASOLINE/LPG MODELS WITHOUT OUTRIGGERS) (GASOLINE/LPG MODELS WITH OUTRIGGERS) 6 - 18 GS-3384 Part No. 82259...
  • Page 207 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 19...

  • Page 208: (From Serial Number 40044 To 40067)

    ELECTRONIC CONTROL MODULE POWER TO ENGINE ECM LOCKOUT TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN FUSE LINK STARTER - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7147 6 - 20 GS-3384 Part No. 82259...
  • Page 209 PLAT PLATFORM OVERLOAD DOWN DIAGNOSTIC LIMIT PRESSURE DISPLAY SWITCH SWITCH (OPTION) ELECTRONIC CONTROL MODULE 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7147 Part No. 82259 GS-3384 6 - 21...
  • Page 210 PIN2 LIFT ENABLE LOW BN13 PIN4 DOWN PIN3 PLATFORM & OUTRIGGER POUT1 PIN4 UP/DOWN TS21 DOWN ALARM POUT1 PIN11 ALARM PIN11 PLATFORM CONTROLS PLATFORM CONTROLS (GASOLINE/LPG MODELS WITHOUT OUTRIGGERS) (GASOLINE/LPG MODELS WITH OUTRIGGERS) 6 - 22 GS-3384 Part No. 82259...
  • Page 211 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 23...

  • Page 212: (From Serial Number 40068 To Gs8403-40131)

    ELECTRONIC CONTROL MODULE POWER TO J1-C11 ENGINE ECM LOCKOUT TS69 TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN FUSE LINK STARTER - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7147 6 - 24 GS-3384 Part No. 82259...
  • Page 213 PLAT PLATFORM OVERLOAD DOWN DIAGNOSTIC LIMIT PRESSURE DISPLAY SWITCH SWITCH (OPTION) ELECTRONIC CONTROL MODULE 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7147 Part No. 82259 GS-3384 6 - 25...
  • Page 214 PIN2 LIFT ENABLE LOW BN13 PIN4 DOWN PIN3 PLATFORM & OUTRIGGER POUT1 PIN4 UP/DOWN TS21 DOWN ALARM POUT1 PIN11 ALARM PIN11 PLATFORM CONTROLS PLATFORM CONTROLS (GASOLINE/LPG MODELS WITHOUT OUTRIGGERS) (GASOLINE/LPG MODELS WITH OUTRIGGERS) 6 - 26 GS-3384 Part No. 82259...
  • Page 215 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 27...

  • Page 216: (From Serial Number Gs8403-40132 To Gs8403-40212)

    ELECTRONIC CONTROL MODULE POWER TO J1-C11 ENGINE ECM LOCKOUT TS69 TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN FUSE LINK STARTER - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7147 6 - 28 GS-3384 Part No. 82259...
  • Page 217 PLAT PLATFORM OVERLOAD DOWN DIAGNOSTIC LIMIT PRESSURE DISPLAY SWITCH SWITCH (OPTION) ELECTRONIC CONTROL MODULE 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7147 Part No. 82259 GS-3384 6 - 29...
  • Page 218 PIN2 LIFT ENABLE LOW BN13 PIN4 DOWN PIN3 PLATFORM & OUTRIGGER POUT1 PIN4 UP/DOWN TS21 DOWN ALARM POUT1 PIN11 ALARM PIN11 PLATFORM CONTROLS PLATFORM CONTROLS (GASOLINE/LPG MODELS WITHOUT OUTRIGGERS) (GASOLINE/LPG MODELS WITH OUTRIGGERS) 6 - 30 GS-3384 Part No. 82259...
  • Page 219 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 31...

  • Page 220: (After Serial Number Gs8403-40212)

    AUXILIARY AUX DOWN J1-C7 TACH DOWN ENABLE J2-B9 GOV. SELECT FUEL SELECT J1-B12 ALT. A ELECTRONIC CONTROL MODULE ALT. B GROUND OIL PRESSURE FUEL LOCKOFF START SOLENOID FUEL PUMP STARTER PUMP FUEL PUMP 6 - 32 GS-3384 Part No. 82259...
  • Page 221 LIMIT LIMIT OIL COOLER SWITCH SWITCH SWITCH SWITCH N.O. N.O. N.O. N.O. LEVEL SENSOR FAN MOTOR MODELS WITHOUT OUTRIGGERS BATTERY 12V (-) ELECTRONIC CONTROL MODULE ELECTRONIC CONTROL MODULE 2 AXIS TILT LEVEL SENSOR Part No. 82259 GS-3384 6 - 33...
  • Page 222 PIN14 ORGR AUTOLEVEL ENABLE BN20 PIN15 SYSTEM STATUS L50 J1 PIN4 PLATFORM UP/DOWN TS20 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 PLATFORM ALARM J3 PIN2 CONTROLS 6 - 34 GS-3384 Part No. 82259...
  • Page 223 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 35...

  • Page 224: (Before Serial Number Gs8404-40302)

    ENGINE SELF TEST SELF TEST SWITCH BK/RD GROUND BN FUEL PUMP BL/WH FORD ENGINE HARNESS STARTER PUMP FUEL PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163B 6 - 36 GS-3384 Part No. 82259...
  • Page 225 OUTRIGGERS BATTERY 12V (-) BN23 BN91 ELECTRONIC CONTROL MODULE J1-C7 AUXILIARY DOWN AUXILIARY DOWN ENABLE J2-C10 J2-B9 J1-B12 AB12 - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163B Part No. 82259 GS-3384 6 - 37...
  • Page 226 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7163B 6 - 38 GS-3384 Part No. 82259...
  • Page 227 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 39...

  • Page 228: (From Serial Number Gs8404-40302 To Gs8405-40504)

    ENGINE SELF TEST SELF TEST SWITCH BK/RD GROUND BN FUEL PUMP BL/WH FORD ENGINE HARNESS STARTER PUMP FUEL PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163C 6 - 40 GS-3384 Part No. 82259...
  • Page 229 OUTRIGGERS BATTERY 12V (-) BN23 BN91 ELECTRONIC CONTROL MODULE J1-C7 AUXILIARY DOWN AUXILIARY DOWN ENABLE J2-C10 J2-B9 J1-B12 AB12 - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163C Part No. 82259 GS-3384 6 - 41...
  • Page 230 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7163C 6 - 42 GS-3384 Part No. 82259...
  • Page 231 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 43...

  • Page 232: Electrical Schematic Ansi Models With Ford Power

    ENGINE SELF TEST SELF TEST SWITCH BK/RD GROUND BN FUEL PUMP BL/WH FORD ENGINE HARNESS STARTER PUMP FUEL PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163E 6 - 44 GS-3384 Part No. 82259...

  • Page 233: Electrical Schematic Ansi Models With Ford Power

    OUTRIGGERS BATTERY 12V (-) BN23 BN91 ELECTRONIC CONTROL MODULE J1-C7 AUXILIARY DOWN AUXILIARY DOWN ENABLE J2-C10 J2-B9 J1-B12 AB12 - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163E Part No. 82259 GS-3384 6 - 45...
  • Page 234 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7163E 6 - 46 GS-3384 Part No. 82259...
  • Page 235 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 47...

  • Page 236: (From Serial Number Gs8405-40540 To Gs8405-40832)

    ENGINE SELF TEST SELF TEST SWITCH BK/RD GROUND BN FUEL PUMP BL/WH FORD ENGINE HARNESS STARTER PUMP FUEL PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163F 6 - 48 GS-3384 Part No. 82259...
  • Page 237 OUTRIGGERS BATTERY 12V (-) BN23 BN91 ELECTRONIC CONTROL MODULE J1-C7 AUXILIARY DOWN AUXILIARY DOWN ENABLE J2-C10 J2-B9 J1-B12 AB12 - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163F Part No. 82259 GS-3384 6 - 49...
  • Page 238 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7163F 6 - 50 GS-3384 Part No. 82259...
  • Page 239 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 51...

  • Page 240: Electrical Schematic Ce Models With Ford Power

    ENGINE SELF TEST SELF TEST SWITCH BK/RD GROUND BN FUEL PUMP BL/WH FORD PUMP ENGINE HARNESS STARTER FUEL PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174 6 - 52 GS-3384 Part No. 82259...

  • Page 241: Electrical Schematic Ce Models With Ford Power

    AB13 N.C. N.C. CR77 LS24 LS25 DOWN ENABLE LOAD HEIGHT SENSE LIMIT DELAY SWITCH LIMIT SWITCH AB14 4700 uF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174 Part No. 82259 GS-3384 6 - 53...
  • Page 242 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7174 6 - 54 GS-3384 Part No. 82259...
  • Page 243 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 55...

  • Page 244: (From Serial Number Gs8404-40302 To Gs8405-40504)

    ENGINE SELF TEST SELF TEST SWITCH BK/RD GROUND BN FUEL PUMP BL/WH FORD PUMP ENGINE HARNESS STARTER FUEL PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174A 6 - 56 GS-3384 Part No. 82259...

  • Page 245: Electrical Schematic Ce Models With Ford Power

    AB13 N.C. N.C. CR77 LS24 LS25 DOWN ENABLE LOAD HEIGHT SENSE LIMIT DELAY SWITCH LIMIT SWITCH AB14 4700 uF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174A Part No. 82259 GS-3384 6 - 57...
  • Page 246 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7174A 6 - 58 GS-3384 Part No. 82259...
  • Page 247 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 59...
  • Page 248 ENGINE SELF TEST SELF TEST SWITCH BK/RD GROUND BN FUEL PUMP BL/WH FORD PUMP ENGINE HARNESS STARTER FUEL PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174B 6 - 60 GS-3384 Part No. 82259...
  • Page 249 AB13 N.C. N.C. CR77 LS24 LS25 DOWN ENABLE LOAD HEIGHT SENSE LIMIT DELAY SWITCH LIMIT SWITCH AB14 4700 uF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174B Part No. 82259 GS-3384 6 - 61...
  • Page 250 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7174B 6 - 62 GS-3384 Part No. 82259...
  • Page 251 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 63...

  • Page 252: (From Serial Number Gs8405-40540 To Gs8405-40617)

    ENGINE SELF TEST SELF TEST SWITCH BK/RD GROUND BN FUEL PUMP BL/WH FORD PUMP ENGINE HARNESS STARTER FUEL PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174B1 6 - 64 GS-3384 Part No. 82259...
  • Page 253 AB13 N.C. N.C. CR77 LS24 LS25 DOWN ENABLE LOAD HEIGHT SENSE LIMIT DELAY SWITCH LIMIT SWITCH AB14 4700 uF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174B1 Part No. 82259 GS-3384 6 - 65...
  • Page 254 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7174B1 6 - 66 GS-3384 Part No. 82259...
  • Page 255 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 67...

  • Page 256: (From Serial Number Gs8405-40618 To Gs8405-40832)

    ENGINE SELF TEST SELF TEST SWITCH BK/RD GROUND BN FUEL PUMP BL/WH FORD PUMP ENGINE HARNESS STARTER FUEL PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174F 6 - 68 GS-3384 Part No. 82259...
  • Page 257 AB13 N.C. N.C. CR77 LS24 LS25 DOWN ENABLE LOAD HEIGHT SENSE LIMIT DELAY SWITCH LIMIT SWITCH AB14 4700 uF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7174F Part No. 82259 GS-3384 6 - 69...
  • Page 258 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7174F 6 - 70 GS-3384 Part No. 82259...
  • Page 259 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 71...

  • Page 260: Electrical Schematic Deutz Models

    HIGH IDLE PLUG TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN GLOW PLUG FUEL HIGH IDLE (OPTION) SHUT OFF SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142 6 - 72 GS-3384 Part No. 82259...
  • Page 261 PLAT PLATFORM OVERLOAD DOWN DIAGNOSTIC LIMIT PRESSURE DISPLAY SWITCH SWITCH (OPTION) ELECTRONIC CONTROL MODULE 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142 Part No. 82259 GS-3384 6 - 73...

  • Page 262: Electrical Schematic Deutz Models

    LIFT ENABLE LOW BN13 PIN3 PIN3 PLATFORM UP/DOWN TS20 PIN4 PLATFORM & OUTRIGGER DOWN PIN4 DOWN UP/DOWN TS21 POUT1 POUT1 ALARM ALARM PIN11 PIN11 PLATFORM CONTROLS PLATFORM CONTROLS (DIESEL MODELS WITHOUT OUTRIGGERS) (DIESEL MODELS WITH OUTRIGGERS) 6 - 74 GS-3384 Part No. 82259...
  • Page 263 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 75...

  • Page 264: (From Serial Number 40044 To 40067)

    HIGH IDLE PLUG TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN GLOW PLUG FUEL HIGH IDLE (OPTION) SHUT OFF SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142 6 - 76 GS-3384 Part No. 82259...
  • Page 265 PLAT PLATFORM OVERLOAD DOWN DIAGNOSTIC LIMIT PRESSURE DISPLAY SWITCH SWITCH (OPTION) ELECTRONIC CONTROL MODULE 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142 Part No. 82259 GS-3384 6 - 77...
  • Page 266 LIFT ENABLE LOW BN13 PIN3 PIN3 PLATFORM UP/DOWN TS20 PIN4 PLATFORM & OUTRIGGER DOWN PIN4 DOWN UP/DOWN TS21 POUT1 POUT1 ALARM ALARM PIN11 PIN11 PLATFORM CONTROLS PLATFORM CONTROLS (DIESEL MODELS WITHOUT OUTRIGGERS) (DIESEL MODELS WITH OUTRIGGERS) 6 - 78 GS-3384 Part No. 82259...
  • Page 267 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 79...

  • Page 268: (From Serial Number 40068 To Gs8403-40131)

    HIGH IDLE PLUG TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN GLOW PLUG FUEL HIGH IDLE (OPTION) SHUT OFF SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142 6 - 80 GS-3384 Part No. 82259...
  • Page 269 PLAT PLATFORM OVERLOAD DOWN DIAGNOSTIC LIMIT PRESSURE DISPLAY SWITCH SWITCH (OPTION) ELECTRONIC CONTROL MODULE 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142 Part No. 82259 GS-3384 6 - 81...
  • Page 270 LIFT ENABLE LOW BN13 PIN3 PIN3 PLATFORM UP/DOWN TS20 PIN4 PLATFORM & OUTRIGGER DOWN PIN4 DOWN UP/DOWN TS21 POUT1 POUT1 ALARM ALARM PIN11 PIN11 PLATFORM CONTROLS PLATFORM CONTROLS (DIESEL MODELS WITHOUT OUTRIGGERS) (DIESEL MODELS WITH OUTRIGGERS) 6 - 82 GS-3384 Part No. 82259...
  • Page 271 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 83...

  • Page 272: (From Serial Number Gs8403-40132 To Gs8403-40212)

    HIGH IDLE PLUG TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN GLOW PLUG FUEL HIGH IDLE (OPTION) SHUT OFF SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142 6 - 84 GS-3384 Part No. 82259...
  • Page 273 PLAT PLATFORM OVERLOAD DOWN DIAGNOSTIC LIMIT PRESSURE DISPLAY SWITCH SWITCH (OPTION) ELECTRONIC CONTROL MODULE 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142 Part No. 82259 GS-3384 6 - 85...
  • Page 274 LIFT ENABLE LOW BN13 PIN3 PIN3 PLATFORM UP/DOWN TS20 PIN4 PLATFORM & OUTRIGGER DOWN PIN4 DOWN UP/DOWN TS21 POUT1 POUT1 ALARM ALARM PIN11 PIN11 PLATFORM CONTROLS PLATFORM CONTROLS (DIESEL MODELS WITHOUT OUTRIGGERS) (DIESEL MODELS WITH OUTRIGGERS) 6 - 86 GS-3384 Part No. 82259...
  • Page 275 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 87...

  • Page 276: Electrical Schematic Ansi Models With Deutz Power

    DOWN AB15 HIGH IDLE CR15 STARTING STARTER 15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164C 6 - 88 GS-3384 Part No. 82259...

  • Page 277: Electrical Schematic Ansi Models With Deutz Power

    OUTRIGGERS BATTERY 12V (-) BN23 BN91 ELECTRONIC CONTROL MODULE J1-C7 AUXILIARY DOWN AUXILIARY DOWN ENABLE J2-C4 J2-C10 J2-B9 AB12 - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164C Part No. 82259 GS-3384 6 - 89...
  • Page 278 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7164C 6 - 90 GS-3384 Part No. 82259...
  • Page 279 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 91...

  • Page 280: (From Serial Number Gs8405-40505 To Gs8405-40832)

    DOWN AB15 HIGH IDLE CR15 STARTING STARTER 15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164G 6 - 92 GS-3384 Part No. 82259...
  • Page 281 OUTRIGGERS BATTERY 12V (-) BN23 BN91 ELECTRONIC CONTROL MODULE J1-C7 AUXILIARY DOWN AUXILIARY DOWN ENABLE J2-C4 J2-C10 J2-B9 AB12 - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164G Part No. 82259 GS-3384 6 - 93...
  • Page 282 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7164G 6 - 94 GS-3384 Part No. 82259...
  • Page 283 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 95...

  • Page 284: Electrical Schematic Ce Models With Deutz Power

    DOWN AB15 HIGH IDLE CR15 STARTING STARTER 15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175A 6 - 96 GS-3384 Part No. 82259...

  • Page 285: Electrical Schematic Ce Models With Deutz Power

    AB13 N.C. N.C. CR77 LS24 LS25 DOWN ENABLE LOAD HEIGHT SENSE LIMIT DELAY SWITCH LIMIT SWITCH AB14 4700 uF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175A Part No. 82259 GS-3384 6 - 97...
  • Page 286 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7175A 6 - 98 GS-3384 Part No. 82259...
  • Page 287 September 2005 Section 6 • Schematics This page intentionally left blank. Part No. 82259 GS-3384 6 - 99...

  • Page 288: (From Serial Number Gs8405-40505 To Gs8405-40832)

    DOWN AB15 HIGH IDLE CR15 STARTING STARTER 15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175K 6 - 100 GS-3384 Part No. 82259...
  • Page 289 AB13 N.C. N.C. CR77 LS24 LS25 DOWN ENABLE LOAD HEIGHT SENSE LIMIT DELAY SWITCH LIMIT SWITCH AB14 4700 uF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175K Part No. 82259 GS-3384 6 - 101...
  • Page 290 -OR- J1 PIN3 PLATFORM & OUTRIGGER UP/DOWN J1 PIN1 Ts21 J1 PIN5 J3 PIN1 - NOTE - PLATFORM ALARM J3 PIN2 MACHINE SHOWN IN THE STOWED CONTROLS POSITION WITH THE POWER OFF ES7175K 6 - 102 GS-3384 Part No. 82259...

  • Page 291: Hydraulic Schematics Component Call-Out And Symbols Legend

    Flow divider/combiner, side to side at divider/combiner 2 position 2 way directional valve the non-steer end valve directional valve Flow divider/combiner, side to side at the steer end Orifice, balances flow front to rear Test port Part No. 82259 GS-3384 6 - 103...

  • Page 292: Hydraulic Schematic (Before Serial Number Gs8404-40297)

    8.7 gpm 0 to 22 gpm 47.7 L/min 32.9 L/min 0 to 83.3 L/min 3650 psi COOLER 251.7 bar (OPTION) 360 psi DRIVE PUMP 24.8 bar 25 psi 1.7 bar HYDRAULIC TANK HS7039B 6 - 104 GS-3384 Part No. 82259...

  • Page 293: Hydraulic Schematic (From Serial Number Gs8404-40297 To Gs8405-40832)

    0.1 gpm FUNCTION 0.38 L/min 2700 to 2900 psi MANIFOLD 186 to 200 bar AUXP GENERATOR (OPTION) 4.5 gpm 17 L/min 3000 psi 207 bar AUXILIARY 2000 psi POWER 137.9 bar UNIT HS7037K Part No. 82259 GS-3384 6 - 105...
  • Page 294 9.1 gpm 0 to 32.5 gpm 40.1 L/min 34.4 L/min 0 to 123 L/min 3750 psi COOLER 258.6 bar (OPTION) 325 psi DRIVE PUMP 22.4 bar 25 psi 1.7 bar HYDRAULIC TANK HS7043C 6 - 106 GS-3384 Part No. 82259...
  • Page 295 0.1 gpm FUNCTION 0.38 L/min 2700 to 2900 psi MANIFOLD 186 to 200 bar AUXP GENERATOR (OPTION) 4.5 gpm 17 L/min 3000 psi 207 bar AUXILIARY 2000 psi POWER 137.9 bar UNIT HS7037K Part No. 82259 GS-3384 6 - 107...
  • Page 296 Section 6 • Schematics September 2005 This page intentionally left blank. 6 - 108 GS-3384 Part No. 82259...
  • Page 297 Genie North America Phone 425.881.1800 Toll Free USA and Canada 800.536.1800 Fax 425.883.3475 Genie Australia Pty Ltd. Phone +61 7 3375 1660 Fax +61 7 3375 1002 Genie China Genie Scandinavia Phone +86 21 53852570...
  • Page 298 Part No. 82259 Rev D...

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