Page 2: Introduction
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.
Page 3: Revision History
January 2013 Revision History Revision Date Section Procedure / Schematic Page / Description 01/2013 Introduction Revision History Added 3 - Maint. A-6, D-5 4 - Repair 6 - Schem. All electrical schematics, 6-3 REFERENCE EXAMPLES: Kubota Engine_Section 2_Specifications. Electronic Version A-6,B-3,C-7_Section 3_Maintenance Procedure.
Page 4 January 2013 REVISION HISTORY, CONTINUED Revision Date Section Procedure / Schematic Page / Description REFERENCE EXAMPLES: Electronic Version Kubota Engine_Section 2_Specifications. A-6,B-3,C-7_Section 3_Maintenance Procedure. Click on any procedure or page number 3-2, 6-4, 9-1_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 5.
Page 5: Serial Number Legend
January 2013 INTRODUCTION Serial Number Legend GS-1930 Model: GS3005A-12345 Serial number: 2005 04/12/05 Model year: Manufacture date: ES0141 Electrical schematic number: 2,714 lb / 1,231 kg Machine unladen weight: GS30 05 A - 12345 500 lb / 227 kg Rated work load (including occupants): Maximum allowable inclination of the chassis: Model Sequence...
Page 6: Safety Rules
Section 1 • Safety Rules January 2013 Safety Rules Personal Safety Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority. Danger Read each procedure thoroughly.
Page 7 Section 1 • Safety Rules January 2013 SAFETY RULES Workplace Safety Be sure to keep sparks, flames and lighted tobacco away from flammable and combustible materials like battery gases and engine fuels. Always have an approved fire extinguisher within easy reach. Be sure that all tools and working areas are properly maintained and ready for use.
Page 8: Table Of Contents
January 2013 Table of Contents Introduction Important Information ..................ii Serial Number Information .................. ii Revision History ....................iii Serial Number Legend ..................v Section 1 Safety Rules General Safety Rules ..................vi Section 2 Specifications Machine Specifications ................2 - 1 Performance Specifications .................
Page 9 January 2013 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Test the Oscillate Axle - GS-90 Models ..........3 - 10 Perform 30 Day Service ..............3 - 11 Perform Engine Maintenance - Deutz Models ........3 - 11 Perform Engine Maintenance - Ford Models ........
Page 10 January 2013 TABLE OF CONTENTS Section 3 Scheduled Maintenance Procedures, continued Checklist C Procedures Test the Platform Overload System (if equipped) ......3 - 29 Down Limit Switch Descent Delay (if equipped)......... 3 - 30 Replace the Engine Air Filter Element - Duetz Models ...... 3 - 31 Replace the Fuel Filter/Water Separator - Deutz Models ....
Page 11 Platform ..................... 4 - 3 Platform Extension Deck ..............4 - 5 Scissor Components Scissor Assembly, GS-3384 and GS-3390 ........4 - 7 Scissor Assembly, GS-4390 ............4 - 13 Scissor Assembly, GS-5390 ............4 - 21 Wear Pads ..................4 - 28 Lift Cylinder(s) ..................
Page 12 January 2013 TABLE OF CONTENTS Section 4 Repair Procedures, continued Manifolds Function Manifold Components - Models with Outriggers ....4 - 72 Function Manifold Components - Models without Outriggers ... 4 - 74 Drive Manifold Components ............. 4 - 76 Oscillate Manifold Components, GS-90 Models (option) ....
Page 13 January 2013 TABLE OF CONTENTS Section 5 Fault Codes Introduction ....................5 - 1 Machine Fault Code Chart ................5 - 3 Ford LRG-425 ECM Fault Code Chart ............5 - 6 Ford DSG-423 ECM Fault Code Chart ............5 - 11 Section 6 Schematics Introduction ....................
Page 14 January 2013 TABLE OF CONTENTS Section 6 Schematics, continued Electrical Schematic - ANSI Models with Ford Power (GS-84 models after serial number GS8407-41311) (GS-90 models from serial number GS9007-43787 to GS9012-48127) ..6 - 24 Electrical Schematic - ANSI Models with Ford Power (GS-84 models after serial number GS8407-41311) (GS-90 models after serial number GS9012-48127) ........
Page 15 January 2013 TABLE OF CONTENTS Section 6 Schematics, continued Electrical Schematic - CE Models with Deutz Power (GS-84 models from serial number GS8406-40833 to GS8410-42031) (GS-90 models from serial number GS9006-42686 to GS9010-47262) ..6 - 60 Electrical Schematic - CE Models with Deutz Power (GS-84 models after serial number GS8410-42031) (GS-90 models from serial number GS9010-47263 to GS9012-48127) ..
Page 16: Gs-84 • Gs-90 Part
January 2013 This page intentionally left blank. GS-84 • GS-90 Part No. 84793...
Page 17: Specifications
Tire weight, new foam-filled (minimum) 265 lbs (Rough terrain) 120 kg Hydraulic system with outriggers 37.5 gallons (including tank), GS-3384 and GS-3390 142 liters Tire diameter x width 33 in x 12 in 83.8 cm x 30 cm Hydraulic system with outriggers 38.25 gallons...
Page 18: Performance Specifications
0.7 mph 40 ft / 39 sec 1.1 km/h 12.2 m / 39 sec Continuous improvement of our products is a Genie policy. Product specifications are Braking distance, maximum subject to change without notice. high range on paved surface 60 inches 152.4 cm...
Page 19: Hydraulic Specifications
Viscosity index Note: Genie specifications require additional equipment and special installation instructions for Cleanliness level, minimum 15/13 the approved optional fluids. Consult the Genie Water content, maximum 200 ppm Service Department before use. Chevron Rando HD oil is fully compatible and mixable with Shell Donax TG (Dexron III) oils.
Page 20: Hydraulic Component Specifications
Installation torque, lubricated 180 ft-lbs 244 Nm Auxiliary power unit Relief valve 2000 psi 137.9 bar Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 GS-84 • GS-90 Part No. 84793...
Page 21: Manifold Component Specifications
SAE No. 10 55 ft-lbs / 75 Nm SAE No. 12 75 ft-lbs / 102 Nm Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. Part No. 84793 GS-84 • GS-90 2 - 5...
Page 22: Ford Lrg-425 Efi Engine
Engine Operator Handbook on your machine. 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. 2 - 6 GS-84 • GS-90 Part No. 84793...
Page 23: Ford Dsg-423 Efi Engine
12V DC Group Quantity Continuous improvement of our products is a Cold cranking ampere @ 0°F 1000A Genie policy. Product specifications are subject to change without notice. Reserve capacity @ 25A rate 200 minutes Part No. 84793 GS-84 • GS-90...
Page 24: Deutz F3L 2011 Engine Deutz D2011L03I Engine
For oil requirements, refer to the Engine Operator Handbook on your machine. Injector opening pressure 3046 psi 210 bar Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 8 GS-84 • GS-90 Part No. 84793...
Page 25 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. 84793 GS-84 • GS-90 2 - 9...
Page 26: Hydraulic Hose And Fitting Torque Specifications
™ SAE Dash size Torque ORFS or 37° JIC fittings and hose ends. Genie specifications require that fittings and hose 14 ft-lbs / 19 Nm ends be torqued to specification when they are 23 ft-lbs / 31.2 Nm removed and installed or when new hoses or fittings are installed.
Page 27 January 2013 Section 2 • Specifications SPECIFICATIONS 10.9 12.9 Part No. 84793 GS-84 • GS-90 2 - 11...
Page 28 Section 2 • Specifications January 2013 This page intentionally left blank. 2 - 12 GS-84 • GS-90 Part No. 84793...
Page 29: Scheduled Maintenance Procedures
Indicates a potentially hazardous Use only Genie approved replacement parts. situation which, if not avoided, Machines that have been out of service for a may result in property damage. period longer than 3 months must complete the Indicates that a specific result is expected after quarterly inspection.
Page 30: Pre-Delivery Preparation Report
Section 3 • Scheduled Maintenance Procedures January 2013 SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend Pre-delivery Preparation Report Note: The following symbols have been used in this The pre-delivery preparation report contains manual to help communicate the intent of the checklists for each type of scheduled inspection. instructions.
Page 31 Date Machine owner Inspected by (print) Inspector signature Inspector title Inspector company Terex South Dakota, Inc USA Genie UK 500 Oak Wood Road The Maltings, Wharf Road PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000...
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Page 33: Maintenance Inspection Report
January 2013 Section 3 • Scheduled Maintenance Procedures Maintenance Inspection Report Model Checklist A - Rev F Y N R Checklist B - Rev F Y N R A-1 Manuals and decals B-1 Battery Serial number A-2 Pre-operation inspect B-2 Electrical wiring A-3 Function tests B-3 Engine air filter Date...
Page 34 Section 3 • Scheduled Maintenance Procedures January 2013 MAINTENANCE INSPECTION REPORT Model Checklist C - Rev E Y N R Checklist E - Rev B Y N R C-1 Platform overload E-1 Test or replace Serial number (if equipped) hydraulic oil C-2 Down limit switch delay Perform every 2400 hours: Date...
Page 35: Checklist A Procedures
Carefully and thoroughly Inspect the Manuals and Decals inspect all decals on the machine for legibility and damage. Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes Result: The machine is equipped with all first.
Page 36: Perform Pre-Operation Inspection
CHECKLIST A PROCEDURES Perform Pre-operation Perform Function Tests Inspection Genie specifications require that this procedure be performed every 8 hours or daily, whichever comes Genie specifications require that this procedure be first. performed every 8 hours or daily, whichever comes first.
Page 37: Perform Engine Maintenance - Ford Models
(Ford part number FPP 194-302) OR the (Deutz part number 0297 9929). Ford DSG-423 EFI Operator Handbook (EDI part number 1060020). Deutz 2011 Operation Manual Genie part number 84794 Ford LRG-425 EFI Operator Handbook Genie part number 84792 Ford DSG-423 EFI Operator Handbook...
Page 38: Test The Oscillate Axle - Gs-90 Models
7 ft / 213 cm to GS-90 Models 9 ft / 274 cm. Genie specifications require that this procedure be 5 Drive the left steer tire into a 4 in / 10 cm deep performed daily or every 8 hours, whichever comes hole.
Page 39: Perform 30 Day Service
(Deutz part number 0297 9929). • A-9 Perform Engine Maintenance - Ford Models Deutz 2011 Operation Manual • B-7 Inspect the Tires, Wheels and Genie part number 84794 Lug Nut Torque • D-4 Replace the Hydraulic Filters Deutz models: • B-4...
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 100 hours or monthly, whichever comes first. Proper maintenance of the fuel filter/water separator is essential for good engine performance.
Page 41: Replace The Drive Hub Oil
Ford DSG-423 EFI Operator Handbook use may cause component damage. See D-3, (EDI part number 1060020). Replace the Drive Hub Oil. Ford LRG-425 EFI Operator Handbook Genie part number 84792 Ford DSG-423 EFI Operator Handbook Genie part number 119488 Part No. 84793 GS-84 •...
Page 42: Checklist B Procedures
• Add 0.004 to the reading of each cell for every 10° / 5.5° C above 80° F / 26.7° C. Genie specifications require that this procedure be • Subtract 0.004 from the reading of each cell for performed every 250 hours or quarterly, whichever every 10°...
Page 43: Inspect The Electrical Wiring
6 Release the safety arm latch, lift the safety arm and rotate to a vertical position. Lock the safety arm in position. Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Note: Be sure that the safety arm is locked in the comes first.
Page 44: Inspect The Engine Air Filter
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 this procedure be tray from moving. performed every 250 hours or quarterly, whichever 3 Remove the air intake hose from the engine comes first.
Page 45: Check And Adjust The Engine Rpm
RPM on the diagnostic display. Refer to Section 2, Specifications. Skip to step 6 if the low idle rpm is correct. Genie specifications require that this procedure be 3 Release the latches on the engine tray and fully performed every 250 hours or quarterly, whichever slide the engine tray out.
Page 46: Check The Exhaust System
Refer to Section 2, Specifications. Skip to step 11 if the high idle rpm is correct. Genie specifications require that this procedure be If the high idle rpm is not correct and the low performed every 250 hours or quarterly, whichever idle was just calibrated, proceed to step 10.
Page 47: Confirm The Proper Brake Configuration
Confirm the Proper Inspect the Tires, Wheels and Brake Configuration Lug Nut Torque Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.
Page 48: Check The Drive Hub Oil Level And Fastener Torque
CHECKLIST B PROCEDURES Check the Drive Hub Oil Level Test the Key Switch and Fastener Torque Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper key switch action and response is essential Genie specifications require that this procedure be to safe machine operation.
Page 49: Test The Emergency Stop
B-10 B-11 Test the Emergency Stop Test the Automotive-style Horn Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever performed every 250 hours or quarterly, whichever comes first.
Page 50: Test The Fuel Select Operation - Ford Models
Result: The LPG indicator light should be on. 6 Start the engine and allow it to run at low idle. Genie specifications require that this procedure be 7 Press high idle button to allow the engine to run performed every 250 hours or quarterly, whichever at high idle.
Page 51: Test The Drive Brakes
B-14 Test the Drive Brakes Test the Drive Speed - Stowed Position Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. performed every 250 hours or quarterly, whichever comes first.
Page 52: Test The Drive Speed - Raised Position
6 Bring the machine to maximum forward drive Genie specifications require that this procedure be speed before reaching the start line. Begin timing when your reference point on the performed every 250 hours or quarterly, whichever machine crosses the start line.
Page 53: Check The Up Limit Switch Drive Cutout And Outriggers Gs-5390
9.1 m inspect the up limit switches and the limit switch cams. 7 Push and hold the auto level button. Activate Genie specifications require that this procedure be and hold the up/down rocker switch in the down performed every 250 hours or quarterly, whichever position.
Page 54: Perform Hydraulic Oil Analysis
B-18 Perform Hydraulic Oil Analysis Inspect the Fuel and Hydraulic Tank Cap Venting Systems Genie specifications require that this procedure be performed every 250 hours or quarterly, whichever Genie specifications require that this procedure be comes first. performed every 250 hours or quarterly, whichever Replacement or testing of the hydraulic oil is comes first.
Page 55: Replace The Engine Air Filter Element - Ford Models
January 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST B PROCEDURES 3 Using a mild solvent, carefully wash the cap B-19 venting system. Dry using low pressure Replace the Engine Air Filter compressed air. Repeat this procedure Element - Ford Models beginning with step 2.
Page 56: Perform Engine Maintenance - Ford Models
Ford LRG-425 EFI Operator Handbook (Ford part number FPP 194-302) OR the Ford DSG-423 EFI Operator Handbook (EDI part number 1060020). Ford LRG-425 EFI Operator Handbook Genie part number 84792 Ford DSG-423 EFI Operator Handbook Genie part number 119488 3 - 28 GS-84 •...
Page 57: Checklist C Procedures
B9 terminal of the terminal strip. 8 Securely connect a jumper wire from terminal Genie specifications require that this procedure be A10 of the terminal strip to terminal B9 of the performed every 500 hours or six months, terminal strip.
Page 58: Down Limit Switch Descent Delay (If Equipped)
B9 of the terminal strip. 16 Turn the key switch to platform control. Genie specifications require that this procedure be 17 Fully raise the platform. Release the joystick. performed every 250 hours or quarterly, whichever comes first.
Page 59: Replace The Engine Air Filter Element - Duetz Models
5 Measure the distance between the working surface and the platform deck. Maintaining the engine air filter in good condition is essential to good engine performance and service GS-3384 95 to 107 inches life. Failure to perform this procedure can lead to GS-3390 2.4 to 2.7 m...
Page 60: Replace The Fuel Filter/Water Separator - Deutz Models
Replace the Diesel Fuel Filter/Water Separator - Deutz Models Genie specifications require that this procedure be performed every 500 hours or semi-annually, whichever comes first. Replacing the diesel fuel filter/water separator is essential to good engine performance and service life.
Page 61: Perform Engine Maintenance - Deutz Models
119488 Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil Genie specifications require that this procedure be performed every 500 hours or semi-annually, whichever comes first. The hydraulic tank is a vented-type tank. The breather cap has an internal air filter that can become clogged or, over time, can deteriorate.
Page 62: Checklist D Procedures
Proceed to step 4. Result: The measurement is less than inch / 8 mm. Replace both wear pads. Genie specifications require that this procedure be 4 Measure the thickness of each platform scissor performed every 1000 hours or annually, whichever arm wear pad at the non-steer end of the comes first.
Page 63: Check The Free-Wheel Configuration
5 Manually rotate each wheel at the non-steer end. Result: Each wheel should rotate with minimum effort. Genie specifications require that this procedure be 6 Engage the drive hubs by turning over performed every 1000 hours or annually, whichever the hub disconnect caps. Rotate each wheel to comes first.
Page 64: Replace The Drive Hub Oil
CHECKLIST D PROCEDURES Replace the Drive Hub Oil Replace the Hydraulic Filters Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 1000 hours or annually, whichever performed every 1000 hours or annually, whichever comes first.
Page 65 January 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST D PROCEDURES 4 Remove the filter housing using a wrench on the Replace the Hydraulic Tank Return Filter nut provided on the bottom of the housing. 17 Open the function manifold tray door. 5 Remove the filter element from the housing.
Page 66: Test The Oscillate Axle - Gs-90 Models
4 At the ground controls, turn the key switch to platform controls and pull out the red Emergency Stop button. Genie specifications require that this procedure be 5 Pull out the red Emergency Stop button on the performed every 1000 hours or annually, whichever platform controller and start the engine.
Page 67 9 Raise the platform until the green LED comes Result: The volt meter reads 0V DC. Do not proceed. Contact the Genie Service Department 10 Using a volt meter, check for voltage by for assistance. connecting the positive lead to relay K11,...
Page 68 This simulates closing the right rear limit Result: The volt meter reads 0V DC. Do not switch causing the left oscillate cylinder to proceed. Contact the Genie Service Department extend. for assistance. Result: No movement. Verify there is voltage on 18 Push in the red Emergency Stop button on the the jumper wire.
Page 69: Perform Engine Maintenance - Deutz Models
1000 hours or annually, whichever comes first. Required maintenance procedures and additional engine information is available in the Deutz 2011 Operation Manual (Deutz part number 0297 9929). Deutz 2011 Operation Manual Genie part number 84794 Part No. 84793 GS-84 • GS-90 3 - 41...
Page 70: Checklist E Procedures
2 Start the engine. 3 Raise the platform approximately 18 feet / 5.5 m from the ground. Genie specifications require that this procedure be performed every 2000 hours or every two years, 4 Release the safety arm latch, lift the safety arm whichever comes first.
Page 71 January 2013 Section 3 • Scheduled Maintenance Procedures CHECKLIST E PROCEDURES 9 Close the two hydraulic shutoff valves located at 11 Tag, disconnect and plug the two suction hoses the hydraulic tank. that are attached to the hydraulic tank shutoff valves or tank. Component damage hazard.
Page 72: Perform Engine Maintenance - Ford Models
28 Open the hydraulic tank shutoff valves. Component damage hazard. Ford LRG-425 EFI Operator Handbook Be sure to open the two hydraulic Genie part number 84792 tank shutoff valves and prime the pump after installing the hydraulic Ford DSG-423 EFI Operator Handbook tank.
Page 73: Perform Engine Maintenance - Deutz Models
Deutz 2011 Operation Manual Deutz 2011 Operation Manual (Deutz part number 0297 9929). (Deutz part number 0297 9929). Deutz 2011 Operation Manual Genie part number 84794 Deutz 2011 Operation Manual Genie part number 84794 Part No. 84793 GS-84 •...
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Page 75 Be sure that all necessary tools and parts are situation which, if not avoided, available and ready for use. could result in death or serious Use only Genie approved replacement parts. injury. Read each procedure completely and adhere Indicates a potentially hazardous to the instructions.
Page 76: Platform Controls
Open the control box lid. For further information or assistance, consult the 3 Visually locate the circuit board mounted to the Genie Industries Service Department. inside of the platform control box lid. 4 Secure the control box lid in a level position.
Page 77: Platform Components
January 2013 Section 4 • Repair Procedures Platform Components 4 Cut the zip ties that secure the power to platform wiring to the bottom of the platform. Platform Component damage hazard. Be sure not to cut the power to How to Remove the Platform platform wiring.
Page 78 Section 4 • Repair Procedures January 2013 PLATFORM COMPONENTS 15 Remove the AC outlet box and bracket from the 20 Place a lifting strap from a second overhead platform and lay them off to the side. Do not crane under the platform at the non-steer end of disconnect the wiring.
Page 79: Platform Extension Deck
January 2013 Section 4 • Repair Procedures PLATFORM COMPONENTS 7 Attach a strap from the platform extension deck railings to the carriage on the forklift to help Platform Extension Deck support the platform extension deck. 8 Remove the three V-roller and extension deck How to Remove a Platform lock bracket mounting fasteners from the Extension Deck...
Page 80: Scissor Components
Section 4 • Repair Procedures January 2013 Scissor Components Non-steer End Steer End Platform centering link 11 Number 3 outer arm Number 3 inner arm 12 Lift cylinder rod-end pivot pin Number 3 center pivot pins 13 Number 3 pivot pins (steer end) Number 3 pivot pins (non-steer end) 14 Number 2 center pivot pins Number 2 outer arm...
Page 81: Scissor Assembly, Gs-3384 And Gs-3390
5 Use a soft metal drift to remove the lift cylinder rod-end pivot pin (index #12). Lower the rod Scissor Assembly, end of the lift cylinder down onto the number 2 GS-3384 and GS-3390 inner arm (index #6). Crushing hazard. The lift cylinder How to Disassemble the...
Page 82 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 10 Place a rod through the cable tray pivot pin and 17 Use a slide hammer to remove both number 3 twist to remove the pin. Lower the cable tray pivot pins (index #13) from the steer end of the down.
Page 83 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 25 Lower the number 1 outer arm (index #16) onto 35 Remove the pin retaining fasteners from the the block. cable tray pivot pin at the cross tube of the number 2 inner arm (index #6). Crushing hazard.
Page 84 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 43 Use a slide hammer to remove both number 2 50 Place a rod through each chassis centering link pivot pins (index #15) from the steer end of the pivot pin and twist to remove the pin. Rest the machine.
Page 85 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS How to 4 Place a 12 inch / 30 cm block under the center of the scissor arm pair. Lower the scissor arm Disassemble a Scissor Arm Pair pair onto the block. Bodily injury hazard.
Page 86 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS Non-steer End Steer End Platform centering link 13 Number 1 pivot pins (non-steer end) Number 4 outer arm 14 Number 4 inner arm Number 4 center pivot pins 15 Number 4 pivot pins (steer end) Number 4 pivot pins (non-steer end) 16 Number 3 outer arm Number 3 center pivot pins...
Page 87: Scissor Assembly, Gs-4390
January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 4 Secure both ends of the number 4 inner and outer arms (index #14 and #2) together with a Scissor Assembly, GS-4390 strap or other suitable device. 5 Attach a lifting strap from an overhead crane to How to Disassemble the the number 4 inner and outer arms (index #14 Scissor Assembly...
Page 88 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 12 Remove the pin retaining fasteners from the lift 20 Cut the zip ties attaching the hydraulic hoses to cylinder rod-end pivot pin (index #17). Do not the lift cylinder. Lay the hoses out of the way. remove the pin.
Page 89 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 25 Attach a lifting strap from an overhead crane to 32 Secure the non-steer end of the number 2 inner the number 3 inner and outer arms (index #18 and outer arms (index #8 and #20) and the non- and #16) at the steer end of the machine.
Page 90 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 42 Carefully remove the lift cylinder from the 49 Place a rod through the cable tray pivot pin and machine. twist to remove the pin. Lower the cable tray onto the number 1 inner arm (index #10). Crushing hazard.
Page 91 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 54 Remove the pin retaining fasteners from both 61 Attach a lifting strap from an overhead crane to number 2 pivot pins (index #21) at the steer end the number 1 inner and outer arms (index #10 of the machine.
Page 92 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS How to Disassemble a Scissor 2 Attach a lifting strap from a second overhead crane to the end of the inner arm. Arm Pair Note: Attach the lifting strap to the end of the Bodily injury hazard.
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Page 94 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS Non-steer End Steer End Platform centering link 16 Number 1 outer arm Number 5 inner arm 17 Number 1 pivot pins (non-steer end) Number 5 center pivot pins 18 Number 5 outer arm Number 5 pivot pins (non-steer end) 19 Number 5 pivot pins (steer end) Number 4 outer arm...
Page 95: Scissor Assembly, Gs-5390
January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 4 Secure both ends of the number 5 inner and outer arms (index #2 and #18) together with a Scissor Assembly, GS-5390 strap or other suitable device. 5 Attach a lifting strap from an overhead crane to How to Disassemble the the number 5 inner and outer arms (index #2 Scissor Assembly...
Page 96 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 12 Remove the pin retaining fasteners from the 19 Remove the pin retaining fasteners from both upper lift cylinder rod-end pivot pin (index #21). number 4 pivot pins (index #7) at the non-steer Do not remove the pin.
Page 97 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 25 Lower the rod end of the upper lift cylinder onto 33 Place a rod through the cable tray pivot pin and the cross tube of the number 3 inner arm twist to remove the pin.
Page 98 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 38 Attach a lifting strap from an overhead crane to 44 Secure the non-steer end of the number 2 inner the number 3 inner and outer arms (index #8 and outer arms (index #26 and #27) and the and #23) at the non-steer end of the machine.
Page 99 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 54 Carefully remove the lift cylinder from the 61 Place a rod through the cable tray pivot pin and machine. twist to remove the pin. Lower the cable tray onto the number 1 inner arm (index #14). Crushing hazard.
Page 100 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 66 Remove the pin retaining fasteners from both 73 Attach a lifting strap from an overhead crane to number 2 pivot pins (index #28) at the steer end the number 1 inner and outer arms (index #14 of the machine.
Page 101 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS How to Disassemble a Scissor 2 Attach a lifting strap from a second overhead crane to the end of the inner arm. Arm Pair Note: Attach the lifting strap to the end of the Bodily injury hazard.
Page 102: Wear Pads
Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 5 Place a rod through each platform centering link pivot pin and twist to remove the pin. Rest the Wear Pads centering links on the scissor arms. How to Replace the Scissor Arm Wear Pads Platform Scissor Arm Wear Pads: 1 Place a lifting strap from an overhead crane...
Page 103 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 12 Align the holes in the slide blocks with the holes 4 Release the latches on the engine tray and fully in the scissor arms. slide the engine tray out. 13 Install the slide block pivot pins and the pin 5 Insert a 6 inch / 15 cm screwdriver or rod into retaining fasteners.
Page 104: Lift Cylinder(S)
The lift cylinders are double acting hydraulic Crushing hazard. The platform will cylinders. The GS-3384, GS-3390 and GS-4390 fall when the platform slide block use one lift cylinder; the GS-5390 uses two. Each pivot pins are removed if it is not...
Page 105 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 1 Start the engine from the ground controls and 7 Attach a lifting strap from an overhead crane or raise the platform approximately 18 feet / 5.5 m similar lifting device to the lifting eye at the rod from the ground.
Page 106 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 10 Carefully lower the cylinder onto the cross tube GS-5390: of the number 2 inner arm. Protect the cylinder Bodily injury hazard. The rod from damage. counterbalance valves in the lift Component damage hazard.
Page 107 January 2013 Section 4 • Repair Procedures SCISSOR COMPONENTS 3 Lower the platform onto the safety arm. Turn the 7 Attach a lifting strap from an overhead crane or machine off. similar lifting device to the lifting eye at the rod end of the lift cylinder for support.
Page 108 Section 4 • Repair Procedures January 2013 SCISSOR COMPONENTS 8 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. 9 Remove the lift cylinder rod-end pivot pin retaining fastener.
Page 109: Rpm Adjustment
Ford LRG-425 EFI Fuel Injection Diagnosis Engine Fault Codes - (Ford part number 194-306). Ford Models Ford LRG-425 EFI Operator Handbook Genie part number 84792 See 5-6, Engine Fault Codes, Ford Models Ford LRG-425 EFI Service Manual Genie part number...
Page 110: Flex Plate
Section 4 • Repair Procedures January 2013 ENGINES Ford LRG425: Flex Plate 3 Remove the hose clamp from the air cleaner hose that connects to the throttle body. The flex plate couples the engine to the pump. The 4 Disconnect the valve cover vent hose from the flex plate is bolted to the engine flywheel and has a air cleaner.
Page 111 January 2013 Section 4 • Repair Procedures ENGINES 8 Remove the ground wire for the LPG solenoid All models: from the ECM mounting fastener. 15 Center a lifting jack under the engine oil pan. 9 Remove the engine ECM mounting bracket 16 Place a wood block between the lifting jack and fasteners.
Page 112 Section 4 • Repair Procedures January 2013 ENGINES How to Remove the Flex Plate - How to Install the Flex Plate Deutz Models 1 Install the flex plate onto the engine flywheel with the raised spline towards the pump. 1 Release the latches on the engine tray and fully slide the engine tray out.
Page 113 January 2013 Section 4 • Repair Procedures ENGINES 4 Install the pump coupler onto the pump shaft with the set screw toward the pump. Leave the appropriate gap between coupler and pump end plate for your engine. Bell housing bolt torque sequence (Ford LRG425) pump pump shaft...
Page 114 Section 4 • Repair Procedures January 2013 ENGINES 7 Ford LRG-425 and Deutz models: Torque the bell housing mounting bolts labeled "C" in sequence to 40 ft-lbs / 54 Nm. Ford DSG-423 models: Torque the bell housing mounting bolts labeled "A" and "B" in sequence to 40 ft-lbs / 54 Nm and the mounting bolts labeled "C"...
Page 115: Ground Controls
• 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 116 Section 4 • Repair Procedures January 2013 GROUND CONTROLS How to Adjust the Stowed Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than specifications could cause the diagnostic display blue platform up button machine to tip over resulting in...
Page 117 January 2013 Section 4 • Repair Procedures GROUND CONTROLS Models with software revision C0 or higher: 1 Pull out the red Emergency Stop button to the on position at the platform controls. 2 Push in the red Emergency Stop button to the off position at the ground controls.
Page 118 Section 4 • Repair Procedures January 2013 GROUND CONTROLS How to Adjust the High Torque Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than specifications could cause the diagnostic display machine to tip over resulting in blue platform up button...
Page 119 January 2013 Section 4 • Repair Procedures GROUND CONTROLS Models with software revision C0 or higher: 1 Pull out the red Emergency Stop button to the on position at the platform controls. 2 Push in the red Emergency Stop button to the off position at the ground controls.
Page 120 Section 4 • Repair Procedures January 2013 GROUND CONTROLS How to Adjust the Raised Drive Speed Tip-over hazard. Do not adjust the lift and/or drive speed higher than specified in this procedure. Setting drive speed greater than specifications could cause the diagnostic display machine to tip over resulting in blue platform up button...
Page 121 January 2013 Section 4 • Repair Procedures GROUND CONTROLS Models with software revision C0 or higher: 1 Pull out the red Emergency Stop button to the on position at the platform controls. 2 Push in the red Emergency Stop button to the off position at the ground controls.
Page 122 Section 4 • Repair Procedures January 2013 GROUND CONTROLS How to Adjust the Lift Speed 1 Pull out the red Emergency Stop button to the on position at the platform controls. 2 Push in the red Emergency Stop button to the off position at the ground controls.
Page 123 January 2013 Section 4 • Repair Procedures GROUND CONTROLS How to Adjust the Platform Lower Speed 1 Pull out the red Emergency Stop button to the on position at the platform controls. 2 Push in the red Emergency Stop button to the off position at the ground controls.
Page 124 Section 4 • Repair Procedures January 2013 GROUND CONTROLS How to Adjust the Platform Settling Speed 1 Pull out the red Emergency Stop button to the on position at the platform controls. 2 Push in the red Emergency Stop button to the off position at the ground controls.
Page 125 January 2013 Section 4 • Repair Procedures GROUND CONTROLS How to Adjust the Steer Speed 1 Pull out the red Emergency Stop button to the on position at the platform controls. 2 Push in the red Emergency Stop button to the off position at the ground controls.
Page 126: Software Configuration
Section 4 • Repair Procedures January 2013 GROUND CONTROLS Machine Option Definitions Software Configuration Descent Delay: This option halts descent when the down limit switch is activated. All controls must be The Electronic Control Module (ECM) contains released for 4 to 6 seconds before descent is re- programming for all configurations of the GS-84 enabled.
Page 127 January 2013 Section 4 • Repair Procedures GROUND CONTROLS Generator, 3kW: If drive or lift function is operated 7 Press the lift function enable button to activate while the generator is ON, the generator will turn the model/power option. OFF while the function is operating. After stopping Result: is showing in the diagnostic SELECT MODEL...
Page 128 Section 4 • Repair Procedures January 2013 GROUND CONTROLS 14 Models with platform overload (option): Use 17 Use the yellow platform down arrow to scroll to the yellow platform down arrow to scroll to generator option. overload. Result: is showing in the GENERATOR AUTO Result: is showing in the diagnostic...
Page 129 January 2013 Section 4 • Repair Procedures GROUND CONTROLS 20 Use the yellow platform down arrow to scroll to CE models with all software revisions: generator option. 1 Turn the key switch to ground controls and pull Result: is showing in the out the red Emergency Stop buttons to the on GENERATOR OFF diagnostic display window.
Page 130 Section 4 • Repair Procedures January 2013 GROUND CONTROLS 5 Press the lift function enable button. 10 Models with software revisions F0, E0, D0 and lower: Use the yellow platform down arrow Result: is showing in the DUAL FUEL to scroll to lift/drive cutout. diagnostic display window.
Page 131 January 2013 Section 4 • Repair Procedures GROUND CONTROLS 15 Use the yellow platform down arrow to scroll to 18 Use the yellow platform down arrow to scroll to sim operation. outriggers option. Result: is showing in the Result: is showing in the SIM OPERATION OFF OUTRIGGERS AUTO diagnostic display window.
Page 132: Level Sensor - Models Without Outriggers
Section 4 • Repair Procedures January 2013 GROUND CONTROLS CE models with all software revisions: Level Sensor - 22 Use the yellow platform down arrow to scroll to return to the main menu. Models without Outriggers Result: is showing in the RETURN TO MAIN MENU diagnostic display window.
Page 133 January 2013 Section 4 • Repair Procedures GROUND CONTROLS 6 Tag and disconnect the wire harness from the 9 Connect the wire harness to the level sensor. level sensor. 10 Turn the key switch to platform control and pull 7 Remove the level sensor retaining fasteners. out the red Emergency Stop buttons to the on Remove the level sensor from the machine.
Page 134: Level Sensor - Models With Outriggers
Section 4 • Repair Procedures January 2013 GROUND CONTROLS 19 Remove the blocks from under both wheels. Level Sensor - 20 Lower the machine and remove the jack. Models with Outriggers 21 Center a lifting jack under the drive chassis at the engine side of the machine.
Page 135 January 2013 Section 4 • Repair Procedures GROUND CONTROLS 3 Remove the ground control panel retaining 11 Install the new level sensor onto the machine fasteners and open the panel. with the "X" on the level sensor base closest to the steer end of the machine.
Page 136 Section 4 • Repair Procedures January 2013 GROUND CONTROLS 12 Connect the wire harness to the level sensor. 20 Adjust the front-to-back axis of the level sensor until the multimeter reads 2.43V DC. Tap the 13 Turn the key switch to platform control and pull top of the level sensor lightly with fingers after out the red Emergency Stop buttons to the on each turn of an adjusting nut.
Page 137 January 2013 Section 4 • Repair Procedures GROUND CONTROLS 30 Lower the machine onto the blocks. 39 Lower the machine onto the blocks. 31 Pull out the red Emergency Stop button to the 40 Raise the platform approximately 16 feet / 5 m. on position at platform controls.
Page 138 Section 4 • Repair Procedures January 2013 GROUND CONTROLS 48 Lower the machine onto the blocks. 57 Lower the machine onto the blocks. 49 Raise the platform approximately 16 feet / 5 m. 58 Raise the platform approximately 16 feet / 5 m. Result: The platform stops raising and the tilt Result: The platform stops raising and the tilt alarm will sound at 180 beeps per minute.
Page 139: Engine Fault Codes - Ford Models
January 2013 Section 4 • Repair Procedures GROUND CONTROLS 4 Move and hold the run/test toggle switch to the test position. Engine Fault Codes - Result: The check engine light should turn on. Ford Models The check engine light should begin to blink. 5 Continue to hold the run/test toggle switch in the How to Retrieve Engine Fault test position.
Page 140 Section 4 • Repair Procedures January 2013 GROUND CONTROLS How to Clear Engine Fault Codes from the ECM Note: Perform this procedure with the engine off and the key switch in the off position. 1 Locate the battery under the ground control panel.
Page 141: Hydraulic Pumps
January 2013 Section 4 • Repair Procedures Hydraulic Pumps 3 Ford models: Close the valve on the LPG tank, then disconnect the hose from the tank (if Lift/Steer Pump equipped). Move the fuel select toggle switch at the ground controls to the LPG position. Note: When removing a hose assembly or fitting, Deutz models: Hold the manual fuel shutoff the O-ring on the fitting and/or hose end must be...
Page 142 Section 4 • Repair Procedures January 2013 HYDRAULIC PUMPS How to Remove the 3 Insert a 6 inch / 15 cm screwdriver or rod into the engine tray lock hole located near the Lift/Steer Pump engine tray roller wheels to prevent the engine tray from moving.
Page 143: Drive Pump
Sundstrand-Sauer service center. Contact the 4 Support the drive pump with a suitable lifting Genie Industries Service Department to locate device and remove the two drive pump your local authorized service center. mounting fasteners.
Page 144: Manifolds
Section 4 • Repair Procedures January 2013 HYDRAULIC PUMPS How to Prime the Pump 3 Ford models: Close the valve on the LPG tank, then disconnect the hose from the tank Component damage hazard. Be (if equipped). Move the fuel select toggle switch sure that the hydraulic tank shutoff at the ground controls to the LPG position.
Page 145 January 2013 Section 4 • Repair Procedures HYDRAULIC PUMPS How to Adjust the Pump Neutral 9 Turn the adjustment screw in a clockwise direction to a position halfway between the Models with Eaton Pumps: positions noted in steps 7 and 8. 10 While holding the adjustment screw in position, 1 Raise the drive wheels off the ground and set tighten the adjustment screw locknut.
Page 146: Function Manifold Components - Models With Outriggers
Section 4 • Repair Procedures January 2013 Manifolds Function Manifold Components - Models with Outriggers The function manifold is located in the chassis tray on the ground controls side of the machine. Index Schematic Description Item Function Torque Check valve, 5 psi / 0.3 bar ........
Page 147 January 2013 Section 4 • Repair Procedures MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Part No. 84793 GS-84 • GS-90 4 - 73...
Page 148: Function Manifold Components - Models Without Outriggers
Section 4 • Repair Procedures January 2013 MANIFOLDS Function Manifold Components - Models without Outriggers The function manifold is located in the chassis tray on the ground controls side of the machine. Index Schematic Description Item Function Torque Check valve, 5 psi / 0.3 bar ........
Page 149 January 2013 Section 4 • Repair Procedures MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Part No. 84793 GS-84 • GS-90 4 - 75...
Page 150: Drive Manifold Components
Section 4 • Repair Procedures January 2013 MANIFOLDS Drive Manifold Components The drive manifold is located under the function manifold. Index Schematic Description Item Function Torque Flow divider/combiner valve ....EA ..Controls flow to front and rear drive motors ..........50 ft-lbs / 68 Nm Orifice - Plug, 0.043 inch / 1.1 mm ..
Page 151 January 2013 Section 4 • Repair Procedures MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Part No. 84793 GS-84 • GS-90 4 - 77...
Page 152: Oscillate Manifold Components, Gs-90 Models (Option)
Section 4 • Repair Procedures January 2013 MANIFOLDS Oscillate Manifold Components, GS-90 Models (option) The oscillate manifold is located under the function manifold. Index Schematic Description Item Function Torque Solenoid valve, 2 position 2 way ..DA ..Oscillate activation ........25 ft-lbs / 34 Nm Relief valve, 3500 psi / 241.3 bar ..
Page 153 January 2013 Section 4 • Repair Procedures MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Part No. 84793 GS-84 • GS-90 4 - 79...
Page 154: Welder Manifold Components, (Option)
Section 4 • Repair Procedures January 2013 MANIFOLDS Welder Manifold Components, (option) The welder manifold is located under the drive manifold. Index Schematic Description Item Function Torque Directional valve ........ FA ..Diverter valve ........ 80-90 ft-lbs / 108-122 Nm Orifice disc, 0.030 inch / .76 mm ..
Page 155 January 2013 Section 4 • Repair Procedures MANIFOLDS Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic Y108 Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic Part No. 84793 GS-84 • GS-90 4 - 81...
Page 156: Valve Adjustments - Function Manifold
5 Determine the test weight for your machine. Refer to the specifications below. Valve Adjustments - Function Manifold Rated work load at full height, maximum GS-3384 and GS-3390 2500 lbs How to Adjust the System Relief 1135 kg Valve GS-4390...
Page 157 3500 psi / 241 bar. Additional test weight Result: The platform should lift and fully raise. Proceed to step 13. GS-3384 and GS-3390 500 lbs 227 kg Result: The platform does not fully raise OR raises too easily. Proceed to step 10.
Page 158: Valve Adjustments - Drive Manifold
Section 4 • Repair Procedures January 2013 MANIFOLDS How to Adjust the Steer Relief Valve Valve Adjustments - Drive Manifold 1 Connect a 0 to 3000 psi / 0 to 250 bar pressure gauge to the test port (item AB) on the function How to Adjust the Charge manifold.
Page 159: Generator Manifold Components
January 2013 Section 4 • Repair Procedures MANIFOLDS Generator Manifold Components The generator manifold is located below the ground controls. Index Schematic Description Item Function Torque Solenoid valve, 2 position 3 way ..... AL ..Generator on/off ........25 ft-lbs / 34 Nm Flow regulator, 4.3 gpm / 16.3 L/min ..
Page 160: Valve Adjustments - Generator Manifold
Section 4 • Repair Procedures January 2013 MANIFOLDS 5 Connect the positive and negative leads from a multimeter of sufficient capacity to the electrical Valve Adjustments - outlet at the generator. Generator Manifold Result: The reading on the multimeter should be 112 to 118V AC.
Page 161: Valve Coils
January 2013 Section 4 • Repair Procedures MANIFOLDS 7-10 Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromagnetic force which operates the solenoid...
Page 162 Section 4 • Repair Procedures January 2013 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. Voltage spikes naturally occur within a function circuit following the interruption of electrical current to a coil.
Page 163: Fuel And Hydraulic Tanks
January 2013 Section 4 • Repair Procedures Fuel and Hydraulic Tanks 6 Remove the entry ladder mounting fasteners. Remove the entry ladder from the machine. Fuel Tank Crushing hazard. The entry ladder could become unbalanced and fall How to Remove the Fuel Tank when it is removed from the machine if it is not properly Explosion and fire hazard.
Page 164: Hydraulic Tank
Section 4 • Repair Procedures January 2013 FUEL AND HYDRAULIC TANKS 4 Lower the platform onto the safety arm. Turn the engine off. Hydraulic Tank Crushing hazard. Keep hands clear of the safety arm when The primary functions of the hydraulic tank are to lowering the platform.
Page 165 January 2013 Section 4 • Repair Procedures FUEL AND HYDRAULIC TANKS 9 Remove the drain plug from the hydraulic tank and completely drain the tank into a suitable container. Refer to Section 2, Specifications. Bodily injury hazard. Spraying hydraulic oil can penetrate and burn skin.
Page 166: Steer Axle Components
Section 4 • Repair Procedures January 2013 Steer Axle Components 7 Tag, disconnect and plug the hoses from the drive motor. Cap the fittings on the drive motor. Yoke and Drive Motor Bodily injury hazard. Spraying hydraulic oil can penetrate and How to Remove the Yoke burn skin.
Page 167 January 2013 Section 4 • Repair Procedures STEER AXLE COMPONENTS How to Remove a Drive Motor 5 Remove the hose clamps retaining fasteners from the drive motor guard. Remove the hose Component damage hazard. clamps. Repairs to the motor should only 6 Remove the retaining fasteners from the drive be performed by an authorized motor guard.
Page 168: Steer Cylinder
Section 4 • Repair Procedures January 2013 STEER AXLE COMPONENTS 3 Remove the pin retaining fasteners from the rod- end pivot pin. Place a rod through the pin and Steer Cylinder twist to remove the pin. Note: Note the location and the amount of the How to Remove the spacers at the barrel end of the steer cylinder.
Page 169: Oscillating Axle Option (Gs-90 Models)
January 2013 Section 4 • Repair Procedures STEER AXLE COMPONENTS Oscillate Limit Switches LS22, LS23 Oscillating Axle Option The right and left oscillating limit switches, LS22 and LS23 respectively, are normally closed limit (GS-90 models) switches, held in the open position when the machine is on a level surface.
Page 170: Non-Steer Axle Components
Section 4 • Repair Procedures January 2013 Non-steer Axle Components 10-1 3 Remove the drive motor mounting fasteners. Drive Motor and Brake 4 Slide the drive motor shaft out of the brake and remove the drive motor from the machine. How to Remove a Drive Motor 5 Remove the brake from the drive hub.
Page 171: Drive Hub
January 2013 Section 4 • Repair Procedures NON-STEER AXLE COMPONENTS 10-2 10-3 Drive Hub Oscillating Axle See 9-3, Oscillating Axle Option (GS-90 models) How to Remove a Drive Hub Note: When removing a hose assembly or fitting, the O-ring on the fitting and/or hose end must be replaced and then torqued to specification during installation.
Page 172: Outrigger Components
Section 4 • Repair Procedures January 2013 Outrigger Components 11-1 5 Attach a lifting strap from an overhead crane to the barrel end of the outrigger cylinder for Outrigger Cylinder support. Do not apply any lifting pressure. 6 Remove the outrigger cylinder mounting How to Remove an Outrigger fasteners.
Page 173: Platform Overload Components
Secure the weight to the platform. Refer to the chart below. On machines with platform overload systems, proper calibration is essential to safe machine GS-3384 and GS-3390 1878 kg operation. An improperly calibrated platform GS-4390...
Page 174 Section 4 • Repair Procedures January 2013 PLATFORM OVERLOAD COMPONENTS GS-3384, GS-3390 and GS-4390 models: 15 Raise the platform until the position indicator corresponds to the maximum load position of 14 Pull out the red Emergency Stop button to the the capacity indicator decal.
Page 175 Secure the weight to the platform. Refer to the and the engine stops running. chart below. Note: Turning the nut (or adjustment screw) out of GS-3384 and GS-3390 1135 kg the hydraulic line will activate the alarm; turning the nut (or adjustment screw) into the hydraulic line will...
Page 176 32 Pull out the red Emergency Stop button to the on position at the ground controls. Wait 3 seconds and start the engine. GS-3384 Result: The alarm doesn't sound and the engine GS-3390 will start and run. Proceed to step 33.
Page 177 January 2013 Section 4 • Repair Procedures PLATFORM OVERLOAD COMPONENTS 33 Raise the platform until the position indicator Set the maximum height pressure switch corresponds to the maximum load position of 34 Working on platform overload pressure switch 1 the capacity indicator decal. (parallel to the cylinder on early models) with a Tip-over hazard.
Page 178 Section 4 • Repair Procedures January 2013 PLATFORM OVERLOAD COMPONENTS 35 Slowly turn the adjustment screw of the platform 41 Slowly turn the adjustment screw of the platform overload pressure switch into the hydraulic line overload pressure switch into the hydraulic line in 90°...
Page 179 Proceed to step 59. Result: The engine stops running. Using a small screwdriver, turn the screw of the platform overload pressure switch, perpendicular to the GS-3384 cylinder, into the hydraulic line in 90° GS-3390 increments until the alarm does not sound and GS-4390 the engine will start and run.
Page 180 Section 4 • Repair Procedures January 2013 PLATFORM OVERLOAD COMPONENTS All models: 65 Push in the red Emergency Stop button to the off position at the ground controls. Disable the descent delay function 66 Pull out the red Emergency Stop button to the 59 Push in the red Emergency Stop button to the on position at the ground controls.
Page 181 January 2013 Section 4 • Repair Procedures PLATFORM OVERLOAD COMPONENTS Enable the descent delay function Calibrate the down limit switch 76 Push in the red Emergency Stop button to the 84 Turn the key switch to platform control. Start the off position at the ground controls.
Page 182 Section 4 • Repair Procedures January 2013 PLATFORM OVERLOAD COMPONENTS 91 Raise the platform approximately 1 m. 101 Install the cover onto the platform overload pressure switch or switch box and securely 92 Return the safety arm to the stowed position. tighten the cover retaining fasteners.
Page 183 January 2013 Section 5 • Fault Codes Fault Codes Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Be aware of the following hazards and follow generally accepted safe workshop practices.
Page 184 Section 5 • Fault Codes January 2013 FAULT CODES About This Section LED Diagnostic Readout When a malfunction is discovered, the fault code charts in this section will help a service professional pinpoint the cause of the problem. To use this section, basic hand tools and certain pieces of test equipment are required—voltmeter, ohmmeter, pressure gauges.
Page 185 January 2013 Section 5 • Fault Codes Fault Code Chart Fault Code Condition Result Solution SYSTEM READY Green Normal operation Internal ECM error. System shutdown. Replace ECM. INTERNAL ECU FAULT Platform/ECM communication Troubleshoot control cable OR System shutdown. PLATFORM ECU error.
Page 186 Section 5 • Fault Codes January 2013 FAULT CODE CHART Fault Code Condition Result Solution Right front outrigger enable Troubleshoot button OR replace printed button fault at platform Outriggers disabled. RIGHT FRONT circuit board at platform controls. controls. OUTRIG SW FLT Left rear outrigger enable Troubleshoot button OR replace printed button fault at platform...
Page 187 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 188: Ford Lrg425 Ecm Fault Code Chart
Section 5 • Fault Codes January 2013 Ford LRG425 ECM Fault Code Chart Code Problem Cause Solution Heated Oxygen Sensor wiring and/or Closed Loop Multiplier Repair wiring and/or connections OR replace connections open or shorted OR sensor is faulty High (LPG) sensor OR repair vacuum and exhaust leaks.
Page 189 January 2013 Section 5 • Fault Codes FORD LRG425 ECM FAULT CODE CHART Code Problem Cause Solution Battery is faulty OR alternator is not charging OR Replace battery OR repair alternator OR repair System Voltage Low battery supply wiring to ECM is open or shorted. battery supply wiring to ECM.
Page 190 Section 5 • Fault Codes January 2013 FORD LRG425 ECM FAULT CODE CHART Code Problem Cause Solution Camshaft position sensor wiring and/or Be sure system ground connections are in place connections open or shorted OR there is a poor and secure OR repair wiring and/or connections Camshaft Sensor Noise system ground connection OR sensor is faulty.
Page 191 FPP1 Low Voltage FPP1 Higher than IVS Limit If this fault appears on your machine, contact Not used. the Genie Industries Service Department. FPP1 Lower than IVS Limit FPP2 High Voltage FPP2 High Voltage The #1 throttle position sensor wiring and/or...
Page 192 Section 5 • Fault Codes January 2013 FORD LRG425 ECM FAULT CODE CHART Code Problem Cause Solution Max Governor Speed Override ECM needs to be re-programmed OR throttle is Re-program ECM OR repair binding throttle FPP1 Low Voltage sticking open OR there are air leaks between the operation OR repair any air leaks between the throttle body and cylinder head.
Page 193: Ford Dsg423 Ecm Fault Code Chart
Ford DSG-423 AUX DIG3 low EFI Service Manual (EDI part number 1060040). IAT (intake air temperature) high voltage Ford DSG 423 EFI Operator Handbook Genie part number 119488 Part No. 84793 GS-84 • GS-90 5 - 11...
Page 194 Ford DSG-423 Primary loop open OR low-side short to ground 4 EFI Service Manual (EDI part number 1060040). Primary coil shorted 4 Ford DSG 423 EFI Operator Handbook Genie part number 119488 5 - 12 GS-84 • GS-90 Part No. 84793...
Page 195 Ford DSG-423 PWM4 short to power EFI Service Manual (EDI part number 1060040). PWM5 open / ground short Ford DSG 423 EFI Operator Handbook Genie part number 119488 Part No. 84793 GS-84 • GS-90 5 - 13...
Page 196 Section 5 • Fault Codes January 2013 This page intentionally left blank. 5 - 14 GS-84 • GS-90 Part No. 84793...
Page 197 January 2013 Section 6 • Schematics Schematics About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution/burn hazard. Contact with electrically charged circuits Troubleshooting and repair procedures shall be could result in death or serious completed by a person trained and qualified on injury.
Page 198: Electronic Control Module Layout
Section 6 • Schematics January 2013 Electronic Control Module Layout 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 - 2 GS-84 •...
Page 199: Electronic Control Module Pin-Out Legend
January 2013 Section 6 • Schematics Electronic Control Module Pin-Out Legend Electronic Control Module (ECM) J1 Connector J2 Connector Description Description Right Turn Coil Y3 (output) Up Limit Switch LS5 (input) Left Turn Coil Y4 (output) Down Limit Switch LS6 (input) Up Coil Y8 (output) Aux Down Power (input) Brake Coil Y2 / Osc.
Page 200: Ground Controls Wiring Panel Layout
Section 6 • Schematics January 2013 Ground Controls Wiring Panel Layout 2 3 4 5 6 7 9 10 11 12 13 14 15 2 3 4 5 6 7 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 2 3 4 5 6 7 9 10 11 12 13 14 15...
Page 201: Ford Engine Relay Layout
January 2013 Section 6 • Schematics Ford Engine Relay Layout Ford LRG425 F5-15A Power F4-15A F3-20A Relay F2-5A F1-30A Starter Fuel Pump Relay Relay Ford DSG-423 Starter Empty Relay F1-10A F2-5A Fuel Power Pump F3-10A F4-15A Relay Relay F5-15A F6-10A NOTE GS-84: F6 added after serial number GS8407-41311...
Page 202: Wiring Diagram - Platform Control Box
Section 6 • Schematics January 2013 Wiring Diagram - Platform Control Box 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 - 6 GS-84 •...
Page 203: Limit Switch Legend
January 2013 Section 6 • Schematics Limit Switch Legend up limit switch LS5 dual pressure switch LS26 (GS-5390 models) (GS-5390 CE models) (hydraulic tank side) outrigger deployed up limit switch LS5A (all models) (GS-5390 models) • left front LS12 (hydraulic tank side) •...
Page 204: Electrical Schematics Abbreviation And Wire Color Legends
Section 6 • Schematics January 2013 Electrical Schematics Abbreviation and Wire Color Legends Code Description Code Description Code Description Flashing Beacons Battery Quick disconnect Control cable to ground Button Fusible link, battery to alternator Control cable to platform Engine stop Gauge Engine start Resistor, 510 ohm...
Page 205: Electrical Symbols Legend
January 2013 Section 6 • Schematics Electrical Symbols Legend KEY SWITCH Fuse or STARTER PLATFORM Circuit breaker PUMP CONTROL Fusible link Auxiliary pump Engine starter GROUND CONTROL Emergency Stop Hour meter button Key switch N.O. LEVEL SENSOR CIRCUIT BOARD LEVEL Horn SENSOR Flashing beacon...
Page 206: Wiring Harness - Ford Lrg-425 Efi (Gs-84 Models Before Serial Number Gs8406-41197) (Gs-90 Models Before Serial Number Gs9006-43481)
Section 6 • Schematics January 2013 Wiring Harness - Ford LRG-425 EFI Part 1 of 2 (GS-84 models before serial number GS8406-41197) (GS-90 models before serial number GS9006-43481) 361 R 16 361 R 16 INJ + 555 T 16 555 T 16 INJ 1 557 BR-Y 16 557 BR-Y 16...
Page 207 January 2013 Section 6 • Schematics Wiring Harness - Ford LRG-425 EFI Part 2 of 2 (GS-84 models before serial number GS8406-41197) (GS-90 models before serial number GS9006-43481) 361 R 16 361 R 16 361 R 16 361 R 16 FORD 555 T 16 557 BR-Y 16...
Page 208: Wiring Harness - Ford Dsg-423 Efi (Gs-84 Models From Serial Number Gs8406-41197 To Gs8407-41311) (Gs-90 Models From Serial Number Gs9006-43481 To Gs9007-43786)
Section 6 • Schematics January 2013 Wiring Harness - Ford DSG-423 EFI Part 1 of 2 (GS-84 models from serial number GS8406-41197 to GS8407-41311) (GS-90 models from serial number GS9006-43481 to GS9007-43786) IGNITION COILS R 16 R 16 ENGINE ECM Y/BK 18 CONNECTOR W/PK 18...
Page 209: Wiring Harness - Ford Dsg-423 Efi (Gs-84 Models After Serial Number Gs8407-41311) (Gs-90 Models After Serial Number Gs9007-43786)
January 2013 Section 6 • Schematics Wiring Harness - Ford DSG-423 EFI Part 2 of 2 (GS-84 models from serial number GS8406-41197 to GS8407-41311) (GS-90 models from serial number GS9006-43481 to GS9007-43786) HO2S #1 HO2S #2 R 16 R 16 GY/R 18 BK/LG 18 GY/LB 18...
Page 210: Gs-84 Models After Serial Number
Section 6 • Schematics January 2013 Wiring Harness - Ford DSG-423 EFI Part 1 of 2 (GS-84 models after serial number GS8407-41311) (GS-90 models after serial number GS9007-43786) IGNITION COILS R 16 R 16 ENGINE ECM Y/BK 18 CONNECTOR W/PK 18 Y/RD 18 GY/LB 18 Y/BK 18...
Page 211 January 2013 Section 6 • Schematics Wiring Harness - Ford DSG-423 EFI Part 2 of 2 (GS-84 models after serial number GS8407-41311) (GS-90 models after serial number GS9007-43786) HO2S #1 HO2S #2 R 16 R 16 GY/R 18 BK/LG 18 GY/LB 18 GY/LB 18 GY/YL 18...
Page 212: (Gs-90 Models From Serial Number Gs9006-42686 To Gs9006-43480)
Section 6 • Schematics January 2013 Electrical Schematic ANSI Models with Ford Power - Part 1 of 3 (GS-84 models from serial number GS8406-40833 to GS8406-41196) (GS-90 models from serial number GS9006-42686 to GS9006-43480) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL GROUND...
Page 213 January 2013 Section 6 • Schematics Electrical Schematic ANSI Models with Ford Power - Part 2 of 3 (GS-84 models from serial number GS8406-40833 to GS8406-41196) (GS-90 models from serial number GS9006-42686 to GS9006-43480) OIL COOLER (GS-5390) (OPTION) LS5A J2-C12 BATTERY 12V (+) CD13 N.C.
Page 214: (Gs-84 Models From Serial Number Gs8406-40833 To Gs8406-41196)
POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 216: (Gs-90 Models From Serial Number Gs9006-43481 To Gs9007-43786)
Section 6 • Schematics January 2013 Electrical Schematic ANSI Models with Ford Power - Part 1 of 3 (GS-84 models from serial number GS8406-41197 to GS8407-41311) (GS-90 models from serial number GS9006-43481 to GS9007-43786) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL GROUND...
Page 217 January 2013 Section 6 • Schematics Electrical Schematic ANSI Models with Ford Power - Part 2 of 3 (GS-84 models from serial number GS8406-41197 to GS8407-41311) (GS-90 models from serial number GS9006-43481 to GS9007-43786) OIL COOLER (GS-5390) (OPTION) LS5A J2-C12 BATTERY 12V (+) CD13 N.C.
Page 218: (Gs-84 Models From Serial Number Gs8406-41197 To Gs8407-41311)
POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 220: (Gs-84 Models After Serial Number Gs8407-41311)
Section 6 • Schematics January 2013 Electrical Schematic ANSI Models with Ford Power - Part 1 of 3 (GS-84 models after serial number GS8407-41311) (GS-90 models from serial number GS9007-43787 to GS9012-48127) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL GROUND CONTROL CR41...
Page 221: (Gs-84 Models After Serial Number Gs8407-41311)
January 2013 Section 6 • Schematics Electrical Schematic ANSI Models with Ford Power - Part 2 of 3 (GS-84 models after serial number GS8407-41311) (GS-90 models from serial number GS9007-43787 to GS9012-48127) OIL COOLER (GS-5390) (OPTION) LS5A J2-C12 BATTERY 12V (+) CD13 N.C.
Page 222 POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 224: (Gs-90 Models After Serial Number Gs9012-48127)
Section 6 • Schematics January 2013 Electrical Schematic ANSI Models with Ford Power - Part 1 of 3 (GS-84 models after serial number GS8407-41311) (GS-90 models after serial number GS9012-48127) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL GROUND CONTROL CR41 CR42 CR23...
Page 225 January 2013 Section 6 • Schematics Electrical Schematic ANSI Models with Ford Power - Part 2 of 3 (GS-84 models after serial number GS8407-41311) (GS-90 models after serial number GS9012-48127) OIL COOLER (GS-5390) (OPTION) LS5A J2-C12 BATTERY 12V (+) CD13 N.C.
Page 226: (Gs-90 Models After Serial Number Gs9012-48127)
POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 228: (Gs-84 Models From Serial Number Gs8406-40833 To Gs8406-41196)
Section 6 • Schematics January 2013 Electrical Schematic CE Models with Ford Power - Part 1 of 3 (GS-84 models from serial number GS8406-40833 to GS8406-41196) (GS-90 models from serial number GS9006-42686 to GS9006-43480) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A...
Page 229 January 2013 Section 6 • Schematics Electrical Schematic CE Models with Ford Power - Part 2 of 3 (GS-84 models from serial number GS8406-40833 to GS8406-41196) (GS-90 models from serial number GS9006-42686 to GS9006-43480) (GS-5390 ONLY) LS12A OIL COOLER LOWER O-RIG (OPTION) LIMIT SWITCH...
Page 230 Section 6 • Schematics January 2013 Electrical Schematic CE Models with Ford Power - Part 3 of 3 (GS-84 models from serial number GS8406-40833 to GS8406-41196) (GS-90 models from serial number GS9006-42686 to GS9006-43480) EMERGENCY POWER TO PLATFORM STOP WH/RD POWER TO GROUND RD/WH GROUND...
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Page 232 Section 6 • Schematics January 2013 Electrical Schematic CE Models with Ford Power - Part 1 of 3 (GS-84 models from serial number GS8406-41197 to GS8407-41311) (GS-90 models from serial number GS9006-43481 to GS9007-43786) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A...
Page 233 January 2013 Section 6 • Schematics Electrical Schematic CE Models with Ford Power - Part 2 of 3 (GS-84 models from serial number GS8406-41197 to GS8407-41311) (GS-90 models from serial number GS9006-43481 to GS9007-43786) (GS-5390 ONLY) LS12A OIL COOLER LOWER O-RIG (OPTION) LIMIT SWITCH...
Page 234 POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 236 Section 6 • Schematics January 2013 Electrical Schematic CE Models with Ford Power - Part 1 of 3 (GS-84 models from serial number GS8407-41312 to GS8410-42031) (GS-90 models from serial number GS9007-43787 to GS9010-47262) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A...
Page 237 January 2013 Section 6 • Schematics Electrical Schematic CE Models with Ford Power - Part 2 of 3 (GS-84 models from serial number GS8407-41312 to GS8410-42031) (GS-90 models from serial number GS9007-43787 to GS9010-47262) (GS-5390 ONLY) LS12A OIL COOLER LOWER O-RIG (OPTION) LIMIT SWITCH...
Page 238 POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 240: (Gs-84 Models After Serial Number Gs8410-42031)
Section 6 • Schematics January 2013 Electrical Schematic CE Models with Ford Power - Part 1 of 3 (GS-84 models after serial number GS8410-42031) (GS-90 models from serial number GS9010-47263 to GS9012-48127) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A PLATFORM OVERLOAD PRESSURE SWITCH LS26...
Page 241: (Gs-84 Models After Serial Number Gs8410-42031)
January 2013 Section 6 • Schematics Electrical Schematic CE Models with Ford Power - Part 2 of 3 (GS-84 models after serial number GS8410-42031) (GS-90 models from serial number GS9010-47263 to GS9012-48127) (GS-5390 ONLY) LS12A OIL COOLER LOWER O-RIG (OPTION) LIMIT SWITCH N.C.
Page 242: (Gs-84 Models After Serial Number Gs8410-42031)
POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 244: (Gs-84 Models After Serial Number Gs8410-42031)
Section 6 • Schematics January 2013 Electrical Schematic CE Models with Ford Power - Part 1 of 3 (GS-84 models after serial number GS8410-42031) (GS-90 models after serial number GS9012-48127) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A PLATFORM OVERLOAD PRESSURE SWITCH LS26 PS2B 5 OHM...
Page 245 January 2013 Section 6 • Schematics Electrical Schematic CE Models with Ford Power - Part 2 of 3 (GS-84 models after serial number GS8410-42031) (GS-90 models after serial number GS9012-48127) (GS-5390 ONLY) LS12A OIL COOLER LOWER O-RIG (OPTION) LIMIT SWITCH N.C.
Page 246: (Gs-90 Models After Serial Number Gs9012-48127)
POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 248: (Gs-84 Models After Serial Number Gs8406-40833)
Section 6 • Schematics January 2013 Electrical Schematic ANSI Models with Deutz Power - Part 1 of 3 (GS-84 models after serial number GS8406-40833) (GS-90 models from serial number GS9006-42686 to GS9012-48127) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL GROUND CONTROL CR41...
Page 249 January 2013 Section 6 • Schematics Electrical Schematic ANSI Models with Deutz Power - Part 2 of 3 (GS-84 models after serial number GS8406-40833) (GS-90 models from serial number GS9006-42686 to GS9012-48127) OIL COOLER (GS-5390) (OPTION) LS5A J2-C12 BATTERY 12V (+) CD13 N.C.
Page 250: (Gs-84 Models After Serial Number Gs8406-40833)
POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 252 Section 6 • Schematics January 2013 Electrical Schematic ANSI Models with Deutz Power - Part 1 of 3 (GS-84 models after serial number GS8406-40833) (GS-90 models after serial number GS9012-48127) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL GROUND CONTROL CR41 CR42 CR23...
Page 253 January 2013 Section 6 • Schematics Electrical Schematic ANSI Models with Deutz Power - Part 2 of 3 (GS-84 models after serial number GS8406-40833) (GS-90 models after serial number GS9012-48127) OIL COOLER (GS-5390) (OPTION) LS5A J2-C12 BATTERY 12V (+) CD13 N.C.
Page 254 POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
Page 255 January 2013 Section 6 • Schematics This page intentionally left blank. Part No. 84793 GS-84 • GS-90 6 - 59...
Page 256: (Gs-84 Models From Serial Number Gs8406-40833 To Gs8410-42031)
Section 6 • Schematics January 2013 Electrical Schematic CE Models with Deutz Power - Part 1 of 3 (GS-84 models from serial number GS8406-40833 to GS8410-42031) (GS-90 models from serial number GS9006-42686 to GS9010-47262) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A...
Page 257 January 2013 Section 6 • Schematics Electrical Schematic CE Models with Deutz Power - Part 2 of 3 (GS-84 models from serial number GS8406-40833 to GS8410-42031) (GS-90 models from serial number GS9006-42686 to GS9010-47262) (GS-5390 ONLY) LS12A OIL COOLER LOWER O-RIG (OPTION) LIMIT SWITCH...
Page 258 POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
Page 259 January 2013 Section 6 • Schematics This page intentionally left blank. Part No. 84793 GS-84 • GS-90 6 - 63...
Page 260 Section 6 • Schematics January 2013 Electrical Schematic CE Models with Deutz Power - Part 1 of 3 (GS-84 models after serial number GS8410-42031) (GS-90 models from serial number GS9010-47263 to GS12-48127) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A PLATFORM OVERLOAD PRESSURE SWITCH LS26...
Page 261 January 2013 Section 6 • Schematics Electrical Schematic CE Models with Deutz Power - Part 2 of 3 (GS-84 models after serial number GS8410-42031) (GS-90 models from serial number GS9010-47263 to GS9012-48127) (GS-5390 ONLY) LS12A OIL COOLER LOWER O-RIG (OPTION) LIMIT SWITCH N.C.
Page 262 POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 264 Section 6 • Schematics January 2013 Electrical Schematic CE Models with Deutz Power - Part 1 of 3 (GS-84 models after serial number GS8410-42031) (GS-90 models after serial number GS9012-48127) 5A FUSE EMERGENCY STOP KEY SWITCH PLATFORM CONTROL PS2A PLATFORM OVERLOAD PRESSURE SWITCH LS26 PS2B 5 OHM...
Page 265 January 2013 Section 6 • Schematics Electrical Schematic CE Models with Deutz Power - Part 2 of 3 (GS-84 models after serial number GS8410-42031) (GS-90 models after serial number GS9012-48127) (GS-5390 ONLY) LS12A OIL COOLER LOWER O-RIG (OPTION) LIMIT SWITCH N.C.
Page 266 POWER TO GROUND RD/WH GROUND J5 PIN1 DATA LINK (HIGH) J5 PIN4 DATA LINK (LOW) J5 PIN5 OUTRIGGERS (STANDARD ON GS-5390) (OPTION ON GS-3384,3390 and 4390) J5 PIN2 12V DC CD11 CD11 CD12 CD12 PLATFORM CONTROLS VOLTAGE 5V DC PRINTED CIRCUIT BOARD...
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Page 268: Wiring Diagram - 12 Kw Hydraulic Generator (Option)
Section 6 • Schematics January 2013 Wiring Diagram - 12 kW Hydraulic Generator (option) 12.5 kW HYDRAULIC GENERATOR NEUTRAL BUSS BAR NEMA 4 CONTROL BOX 50 AMP 3 POLE CIRCUIT BREAKER WITH INTERGRAL GFI 208 VAC OUTLET ORANGE WHITE BLACK BLACK BLACK 12 GA GREEN...
Page 269 Replace 2 position terminal strip #45 and use 74911 four position terminal strip in its place. Use the name plate from the old 2 position terminal. Add three 6 amp 200 PIV diodes (Genie part number 45762) in the position shown in the schematic.** Part No. 84793 GS-84 •...
Page 270: Hydraulic Schematics Component Call-Out Legend
Section 6 • Schematics January 2013 Hydraulic Schematics Component Call-out Legend Item Function Item Function Item Function Steer circuit High speed bypass Right front outrigger autolevel valve Auxiliary pump circuit High speed bypass Left front outrigger autolevel valve Steer circuit Balances fluid flow from flow Right rear outrigger autolevel valve divider/combiner BO to non-steer end...
Page 271 January 2013 Section 6 • Schematics Hydraulic Symbols Legend Brake Relief valve Filter Check valve Priority flow regulator Fixed displacement pump Hot oil shuttle valve Accumulator Bi-directional variable speed motor Orifice Variable speed motor Proportional solenoid valve Shut off valve Dual acting cylinder Solenoid operated 3 position 4 way...
Page 272: Hydraulic Schematic
Section 6 • Schematics January 2013 Hydraulic Schematic (GS-84 models from serial number GS8404-40297 to GS8407-41529) (GS-90 models from serial number GS9004-41691 to GS9007-45004) Part 1 of 2 RIGHT RIGHT FRONT REAR 2SPD 0.045 in 1.1 mm 0.090 in 2.3 mm 0.035 in 0.9 mm 0.043 inch...
Page 273: Hydraulic Schematic
(GS-84 models from serial number GS8404-40297 to GS8407-41529) (GS-90 models from serial number GS9004-41691 to GS9007-45004) Part 2 of 2 OSCILLATING AXLE OUTRIGGERS (STANDARD ON GS-5390) (GS-90) (OPTION ON GS-3384, GS-3390 AND GS-4390) PLATFORM LIFT CYLINDER LIFT CYLINDER (OPTION) (GS-5390) OVERLOAD...
Page 274: (Gs-84 Models After Serial Number Gs8407-41529)
Section 6 • Schematics January 2013 Hydraulic Schematic (GS-84 models after serial number GS8407-41529) (GS-90 models after serial number GS9007-45004) Part 1 of 2 RIGHT RIGHT FRONT REAR 2SPD 0.045 in 1.1 mm 0.090 in 2.3 mm 0.035 in 0.9 mm 0.043 inch 0.046 inch 1.1 mm...
Page 275 Hydraulic Schematic (GS-84 models after serial number GS8407-41529) (GS-90 models after serial number GS9007-45004) Part 2 of 2 OSCILLATING AXLE OUTRIGGERS (STANDARD ON GS-5390) (GS-90) (OPTION ON GS-3384, GS-3390 AND GS-4390) PLATFORM LIFT CYLINDER LIFT CYLINDER (OPTION) (GS-5390) OVERLOAD (ALL MODELS)
Page 276 Section 6 • Schematics January 2013 This page intentionally left blank. 6 - 80 GS-84 • GS-90 Part No. 84793...
Page 277 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 Scandinavia Genie China Phone +46 31 57 51 00...

This manual is also suitable for:

Gs-3390 Gs-4390 Gs-5390

Genie GS-3384 Service Manual

Introduction

Safety Rules

Specifications

Scheduled Maintenance Procedures

Checklist a Procedures

Scheduled Maintenance Procedures , Continued

Checklist B Procedures

Scheduled Maintenance Procedures , Continued

Checklist C Procedures

Checklist D Procedures

Checklist E Procedures

Repair Procedures

Platform Controls

Platform Components

Scissor Components

Engines

Ground Controls

Hydraulic Pumps

Repair Procedures , Continued

Manifolds

Fuel and Hydraulic Tanks

Steer Axle Components

Non-Steer Axle Components

Outrigger Components

Platform Overload Components

Schematics

Schematics, Continued

Schematics, Continued

Quick Links

Related Manuals for Genie GS-3384

Summary of Contents for Genie GS-3384