Genie GS-3390 Service Manual
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Genie GS-3390 Service Manual

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  • 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. 72863 GS-3390 • GS-4390 • GS-5390...
  • Page 4 July 2007 This page intentionally left blank. GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • 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. 72863 GS-3390 • GS-4390 • GS-5390...
  • Page 6 Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 7: Table Of Contents

    A-2 Perform Pre-operation Inspection ............3 - 8 A-3 Perform Function Tests ..............3 - 8 A-4 Perform Engine Maintenance - Ford models ........3 - 9 A-5 Perform Engine Maintenance - Deutz models ........3 - 9 Part No. 72863 GS-3390 • GS-4390 • GS-5390...
  • Page 8 B-20 Perform Engine Maintenance - Ford Models ........3 - 28 Checklist C Procedure C-1 Test the Platform Overload System (if equipped) ......3 - 29 C-2 Replace the Engine Air Filter Element - Deutz Models ..... 3 - 30 viii GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 9 Controller Adjustments (before serial number GS9003-41523) ..4 - 5 Software Configuration (before serial number GS9003-41523) ..4 - 11 Platform Components Platform ................... 4 - 15 Platform Extension Deck ..............4 - 17 Part No. 72863 GS-3390 • GS-4390 • GS-5390...
  • Page 10 TABLE OF CONTENTS Section 4 Repair Procedures, continued Scissor Components Scissor Assembly, GS-3390 ............4 - 18 Scissor Assembly, GS-4390 ............4 - 24 Scissor Assembly, GS-5390 ............4 - 34 Wear Pads ..................4 - 47 Lift Cylinder(s) .................. 4 - 49 Engines RPM Adjustment ................
  • Page 11 10-2 Drive Hub ..................4 - 121 10-3 Oscillating Axle ................4 - 121 Outrigger Components 11-1 Outrigger Cylinder ................4 - 122 Platform Overload Components 12-1 Platform Overload System ............. 4 - 123 Part No. 72863 GS-3390 • GS-4390 • GS-5390...
  • Page 12 Electrical Schematics Abbreviation and Wire Color Legends ....... 6 - 9 Limit Switch Legend ................... 6 - 10 Electrical Symbols Legend ................. 6 - 12 Electrical Schematic - Platform Overload (option) (before serial number GS9003-41523) ............6 - 13 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 13 Electrical Schematic - CE Models with Ford Power (from serial number GS9005-42204 to 42411) .......... 6 - 72 Electrical Schematic - CE Models with Ford Power (from serial number GS9005-42412 to GS9005-42685) ......6 - 76 xiii Part No. 72863 GS-3390 • GS-4390 • GS-5390...
  • Page 14 (before serial number 40519) ..............6 - 126 Hydraulic Schematic (from serial number 40519 to GS9004-41690) ......... 6 - 128 Hydraulic Schematic (from serial number GS9004-41691 to GS9005-42685) ......6 - 130 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 15: Machine Specifications

    38 psi 2.6 bar For operational specifications, refer to the Continuous improvement of our products is a Operator's Manual. Genie policy. Product specifications are subject to change without notice. Part No. 72863 GS-3390 • GS-4390 • GS-5390 2 - 1...

  • Page 16: Performance Specifications

    Chevron Rykon MV oil is fully compatible and GS-3390 and GS-4390 mixable with Shell Donax TG (Dexron III) oils. GS-5390 Genie specifications require hydraulic oils which are Airborne noise emissions 80 dB designed to give maximum protection to hydraulic Maximum sound level at normal operation workstations...

  • Page 17: Hydraulic Component Specifications

    Charge pump pressure 360 psi equipment and special installation instructions for (before serial number GS9004-41619) 24.8 bar the approved optional fluids. Consult the Genie Industries Service Department before Charge pump pressure 325 psi use.Department before use. (after serial number GS9004-41618) 22.4 bar...
  • Page 18 Relief valve 3000 psi 207 bar Flow rate, maximum 4.5 gpm 17 L/min Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice. 2 - 4 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 19: Manifold Component Specifications

    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. Part No. 72863 GS-3390 • GS-4390 • GS-5390 2 - 5...

  • Page 20: Ford Lrg-425 Efi Engine

    Quantity (after serial number GS9004-41693) Cold cranking ampere @ 0°F 1000A Spark plug gap 0.042 to 0.046 inches 1.07 to 1.17 mm Reserve capacity @ 25A rate 200 minutes 2 - 6 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 21: Deutz F4L 1011F Engine

    Reserve capacity @ 25A rate 200 minutes Extreme operating temperatures may require the use of alternative engine oils. For oil requirements, refer to the Engine Operation Manual on your machine. Part No. 72863 GS-3390 • GS-4390 • GS-5390 2 - 7...

  • Page 22: Deutz F3L 1011F Engine

    Extreme operating temperatures may require the use of Cold cranking ampere @ 0°F 1000A alternative engine oils. For oil requirements, refer to the Engine Operation Manual on your machine. Reserve capacity @ 25A rate 200 minutes 2 - 8 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 23: Deutz F3L 2011 Engine

    Oil viscosity requirements 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. Part No. 72863 GS-3390 • GS-4390 • GS-5390 2 - 9...

  • Page 24: Hydraulic Hose And Fitting Torque Specifications

    O-rings. They are not standard SAE size O-rings. They are SAE O-ring Boss Port available in the O-ring field service kit (Genie part (tube fitting - installed into Aluminum) number 49612). SAE Dash size Torque 2 Lubricate the O-ring before installation.
  • Page 25 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 Part No. 72863 GS-3390 • GS-4390 • GS-5390 2 - 11...

  • Page 26: Part

    Section 2 • Specifications July 2007 This page intentionally left blank. 2 - 12 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 27 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 28: Pre-Delivery Preparation Report

    Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with employer, jobsite and governmental regulations and requirements. 3 - 2 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 29 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 30 Section 3 • Scheduled Maintenance Procedures July 2007 This page intentionally left blank. 3 - 4 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 31: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired Part No. 72863 GS-3390 • GS-4390 • GS-5390 3 - 5...
  • Page 32 After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, remove from service R = repaired 3 - 6 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 33: 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 Result: The machine is equipped with all comes first.

  • Page 34: Perform Pre-Operation Inspection

    CHECKLIST A PROCEDURES REV E Perform Pre-operation Inspection Perform Function Tests Genie specifications require that this procedure be Genie specifications require that this procedure be performed every 8 hours or daily, whichever performed every 8 hours or daily, whichever comes first.

  • Page 35: Perform Engine Maintenance - Ford Models

    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 Deutz 2011 Operation Manual Genie part number 84794 Part No. 72863 GS-3390 • GS-4390 • GS-5390 3 - 9...

  • Page 36: Perform 30 Day Service

    Deutz 2011 models: · B-8 Inspect the Tires and Wheels (including lug nut torque) · D-4 Replace the Fuel Filter/Water Separator - Deutz Models · D-5 Replace the Hydraulic Filters 3 - 10 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 37: Perform Engine Maintenance - Ford Models

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

  • Page 38: Perform Engine Maintenance - Deutz 1011F 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 - 12 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 39: Perform Engine Maintenance - Ford Models

    Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately. Part No. 72863 GS-3390 • GS-4390 • GS-5390 3 - 13...

  • Page 40: 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 requires that this procedure be performed • Subtract 0.004 from the reading of each cell for every 250 hours or quarterly, whichever comes every 10°...

  • Page 41: Inspect The Electrical Wiring

    6 Before serial number 40351: Release the safety arm latch, lift the safety arm and rotate down to a vertical position. Genie requires that this procedure be performed After serial number 40350: Release the safety every 250 hours or quarterly, whichever comes arm latch, lift the safety arm and rotate to a first.

  • Page 42: Perform Engine Maintenance - Deutz 1011F Models

    REV G Perform Engine Maintenance - Check the Exhaust System Deutz 1011F Models Genie requires that this procedure be performed Engine specifications require that this procedure every 250 hours or quarterly, whichever comes be performed every 250 hours or quarterly, first.

  • Page 43: Inspect The Engine Air Filter

    2 Insert a 6 inch / 15 cm screwdriver or rod into the engine tray lock hole located near the Genie requires that this procedure be performed engine tray roller wheels to prevent the engine every 250 hours or quarterly, whichever comes tray from moving.

  • Page 44: Check And Adjust The Engine Rpm

    RPM on the diagnostic display. Refer to Section 2, Specifications. Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes After serial number GS9004-41522: Press first.
  • Page 45 If the high idle rpm is not correct and the low 11 Close and latch the engine slide out tray. idle was just calibrated, proceed to step 10. All other machines, open the engine tray. Proceed to step 8. Part No. 72863 GS-3390 • GS-4390 • GS-5390 3 - 19...

  • Page 46: Confirm The Proper Brake Configuration

    Confirm the Proper Inspect the Tires and Wheels Brake Configuration (including lug nut torque) Genie requires that this procedure be performed Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes first.

  • Page 47: Check The Oil Level In The Drive Hubs

    B-10 Check the Oil Level in Test the Key Switch the Drive Hubs Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Proper key switch action and response is essential Genie requires that this procedure be performed to safe machine operation.

  • Page 48: Test The Emergency Stop

    REV G B-11 B-12 Test the Emergency Stop Test the Automotive-style Horn Genie requires that this procedure be performed Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes every 250 hours or quarterly, whichever comes first.

  • Page 49: 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 requires that this procedure be performed 7 Press high idle button to allow the engine to run every 250 hours or quarterly, whichever comes at high idle.

  • Page 50: Test The Drive Brakes

    B-15 Test the Drive Brakes Test the Drive Speed - Stowed Position Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes Genie requires that this procedure be performed first. every 250 hours or quarterly, whichever comes first.

  • Page 51: Test The Drive Speed - Raised Position

    Begin timing when your reference point on the machine crosses the start line. Genie requires that this procedure be performed 7 Continue at full speed and note the time when every 250 hours or quarterly, whichever comes the machine reference point passes over the first.

  • Page 52: Perform Hydraulic Oil Analysis

    July 2007 CHECKLIST B PROCEDURES REV G B-17 Perform Hydraulic Oil Analysis Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes first. Replacement or testing of the hydraulic oil is essential for good machine performance and service life.

  • Page 53: Inspect The Fuel And Hydraulic Tank Cap Venting Systems

    4 Install the fuel tank cap onto the fuel tank. 5 Remove the breather cap from the hydraulic tank. Genie requires that this procedure be performed every 250 hours or quarterly, whichever comes 6 Check for proper venting. first. Perform this procedure more often if dusty Result: Air passes through the fuel tank cap.

  • Page 54: Replace The Engine Air Filter Element - Ford 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. 3 - 28 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 55: E Checklist C Procedure

    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 semi-annually, terminal strip.

  • Page 56: Replace The Engine Air Filter Element - Deutz Models

    8 Install the air filter canister end cap and connect the end cap retaining clamp. Note: Be sure the air cleaner intake hose is inserted in the hole in the front of the engine slide out tray. 3 - 30 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 57: Perform Engine Maintenance - Deutz Models

    Optional Hydraulic Oil Engine specifications require that this procedure be performed every 500 hours or semi-annually, whichever comes first. Genie specifications require that this procedure be performed every 500 hours or semi-annually, Required maintenance procedures and additional whichever comes first.

  • Page 58: 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, arm wear pad at the non-steer end of the whichever comes first.

  • Page 59: Check The Free-Wheel Configuration

    Collision hazard. Failure to engage the drive hubs could result in death or serious injury and property damage. Genie specifications require that this procedure be performed every 1000 hours or annually, 7 Chock the wheels at the non-steer end of the whichever comes first.

  • Page 60: Replace The Drive Hub Oil

    Replace the Drive Hub Oil Replace the Diesel Fuel Filter/Water Separator - Deutz Models Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Engine specifications require that this procedure Replacing the drive hub oil is essential for good be performed every 1000 hours or annually, machine performance and service life.
  • Page 61 CHECKLIST D PROCEDURES 4 Remove the fuel filter/water separator with a filter wrench. Replace the Hydraulic Filters Genie specifications require that this procedure be performed every 1000 hours or annually, whichever comes first. Replacing the hydraulic filters is essential to good machine performance and service life.

  • Page 62: Replace The Hydraulic Tank Return Filter

    10 Hold the function enable toggle switch in the up direction and activate the platform up function. 11 Inspect the filter and related components to be sure that there are no leaks. 3 - 36 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 63: Perform Engine Maintenance - Deutz Models

    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 Part No. 72863 GS-3390 • GS-4390 • GS-5390 3 - 37...

  • Page 64: C 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. 3 - 38 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 65 23 Install the two suction hoses. 11 Tag, disconnect and plug the two suction hoses 24 Install the tank return hose. that are attached to the hydraulic tank shutoff valves or tank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 3 - 39...

  • Page 66: Perform Engine Maintenance - Deutz 1011F Models

    2, How to Prime the Pump . 29 Install the access plate and install the access plate retaining fasteners. 30 Install the entry ladder and install the entry ladder mounting fasteners. 3 - 40 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 67: Perform Engine Maintenance - Ford Models

    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 Deutz 2011 Operation Manual Genie part number 84794 Part No. 72863 GS-3390 • GS-4390 • GS-5390 3 - 41...

  • Page 68: Perform Engine Maintenance - Deutz 2011 Models

    Ford LRG425 Operator Handbook Deutz 2011 Operation Manual (Ford part number FPP 194-302). Genie part number 84794 Ford LRG 425 Operator Handbook Genie part number 84792 3 - 42 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 69 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 70: Platform Controls

    TS20 OR platform up/down and outrigger up/down toggle switch TS21 circuit board U3 DIP switch SW25 joystick controller JC1 potentiometer red Emergency Stop button P2 4 - 2 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 71: Circuit Boards

    Note: 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. 72863 GS-3390 • GS-4390 • GS-5390 4 - 3...
  • Page 72 11 Close the lid and install the fasteners. Electrocution/burn hazard. Contact with electrically charged circuits could result in death or serious injury. Remove all rings, watches and other jewelry. 4 - 4 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 73: Controller Adjustments (Before Serial Number Gs9003-41523)

    Emergency Stop button P1 platform up/down toggle switch TS66 Note: Select a test area that is firm, level and free function enable toggle switch TS67 of obstructions. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 5...
  • Page 74 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-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 75 ® 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. 72863 GS-3390 • GS-4390 • GS-5390 4 - 7...
  • Page 76 ® 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-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 77 3 to 5 points less 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. 72863 GS-3390 • GS-4390 • GS-5390 4 - 9...
  • Page 78 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-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 79: Software Configuration (Before Serial Number Gs9003-41523)

    6 Close the lid and install the platform control box switch settings to correspond with the lid fasteners. configuration of the machine options, indicated in the chart. See 1-4, DIP Switch Codes Chart. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 11...
  • Page 80 9 Release the toggle switches, push in the red Emergency Stop button to the off position at both the ground and platform controls and turn the key switch to the off position. 4 - 12 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 81 • 10101101 • • • • 01011111 • • • • 00111111 • • • • • 00101111 • • • • • 10101111 Continued to the next page Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 13...
  • Page 82 • • • • • • • • • • • • 00110110 10110110 • • • • • • • • • • • • • 00111001 10110111 4 - 14 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 83: Platform Components

    Crushing hazard. Keep hands clear of the safety arm when 14 Remove the AC power to platform outlet lowering the platform. bracket mounting fasteners. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 15...
  • Page 84 Note: Component damage hazard. The platform railings can be damaged if used to lift the platform. Do not attach the lifting straps to the platform railings. 4 - 16 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 85: Platform Extension Deck

    5 Lift the platform extension deck lock handle. 6 Carefully slide the platform extension deck out until the platform extension deck makes contact with the carriage on the forklift. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 17...

  • Page 86: 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-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 87: Scissor Assembly, Gs-3390

    9 Remove the pin retaining fasteners from the cable tray pivot pin at the number 3 inner arm (index #2). Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 19...
  • Page 88 24 Place a 6 x 6 x 32 inch / 15 x 15 x 80 cm long pivot pins (index #4) from the non-steer end of block across both sides of the chassis under the machine. the barrel end of the lift cylinder. 4 - 20 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 89 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. 72863 GS-3390 • GS-4390 • GS-5390 4 - 21...
  • Page 90 #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-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 91 Note: 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. 72863 GS-3390 • GS-4390 • GS-5390 4 - 23...
  • Page 92 23 Chassis centering link 24 Number 1 pivot pins (steer end) 11 Lift cylinder barrel-end pivot pin 12 Number 1 outer arm 13 Number 1 pivot pins (non-steer end) 4 - 24 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 93: Scissor Assembly, Gs-4390

    (index #17). Do not 4 Secure both ends of the number 4 inner and remove the pin. outer arms (index #14 and #2) together with a strap or other suitable device. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 25...
  • Page 94 3 pivot pins (index #6) at the non-steer Component damage hazard. end of the machine. Do not remove the pins. Hoses can be damaged if they are kinked or pinched. 4 - 26 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 95 (index #8). 44 Remove the pin retaining fasteners from both number 2 pivot pins (index #21) at the steer end of the machine. Do not remove the pins. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 27...
  • Page 96 #12) at the non-steer end of the machine. Note: If further disassembly of the scissor arm pair Do not apply any lifting pressure. is required, see How to Disassemble a Scissor Arm Pair. 4 - 28 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 97 10 Use a slide hammer to remove both number 4 18 Remove the wheel lug nuts. Remove the tire pivot pins (index #15) from the steer end of the and wheel assembly. machine. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 29...
  • Page 98 Note: If further disassembly of the scissor arm pair is required, see How to Disassemble a Scissor Arm Pair. 4 - 30 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 99 42 Carefully remove the lift cylinder from the machine. Crushing hazard. The lift cylinder could become unbalanced and fall when it is removed from the machine if not properly supported by the overhead crane. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 31...
  • Page 100 Arm Pair. machine if not properly supported by the overhead crane. Note: If further disassembly of the scissor arm pair is required, see How to Disassemble a Scissor Arm Pair. 4 - 32 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 101 Note: 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. 72863 GS-3390 • GS-4390 • GS-5390 4 - 33...
  • Page 102 14 Number 1 inner arm 29 Number 1 center pivot pins 15 Lower lift cylinder barrel-end pivot pin 30 Chassis centering link 31 Number 1 pivot pins (steer end) 4 - 34 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 103: Scissor Assembly, Gs-5390

    4 Secure both ends of the number 5 inner and Do not remove the pin. outer arms (index #2 and #18) together with a strap or other suitable device. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 35...
  • Page 104 Do not allow oil to squirt 21 Use a slide hammer to remove both number 4 or spray. pivot pins (index #7) from the non-steer end of the machine. 4 - 36 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 105 (index #10) from the non-steer end of the machine. 42 Use a slide hammer to remove both number 3 pivot pins (index #25) from the steer end of the machine. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 37...
  • Page 106 2 inner arm (index #26) on the connections very slowly to allow hydraulic tank side of the machine. the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 38 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 107 Component damage hazard. outer arms (index #26 and #27) together with a Cables and hoses can be strap or other suitable device. damaged if they are kinked or pinched. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 39...
  • Page 108 Note: If further disassembly of the scissor arm pair is required, see How to Disassemble a Scissor Arm Pair. 4 - 40 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 109 15 Remove the cables from the number 4 inner arm (index #20) and lay the cables off to the side. Component damage hazard. Cables can be damaged if they are kinked or pinched. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 41...
  • Page 110 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 - 42 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 111 42 Use a slide hammer to remove both number 3 pivot pins (index #25) from the steer end of the machine. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 43...
  • Page 112 #27) at the non-steer end of the machine. 58 Remove the strap installed in step 44. Do not apply any lifting pressure. 59 Support the cable tray with an overhead crane. 4 - 44 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 113 72 Attach a lifting strap from an overhead crane to the number 1 inner and outer arms (index #14 and #16) at the steer end of the machine. Do not apply any lifting pressure. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 45...
  • Page 114 2 Attach a lifting strap from a second overhead crane to the end of the inner arm. Note: Attach the lifting strap to the end of the scissor arm that has the casting pointing upwards. 4 - 46 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 115: 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. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 47...
  • Page 116 4 - 48 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 117: Lift Cylinder(S)

    17 Install the new wear pads onto the scissor arm The lift cylinders are double acting hydraulic slide blocks. cylinders. The GS-3390 and GS-4390 use one lift cylinder; the GS-5390 uses two. Each lift cylinder 18 Install the slide blocks onto the chassis.
  • Page 118 6 Attach a lifting strap from an overhead crane or machine if not properly supported. similar lifting device to the lifting eye at the rod end of the lift cylinder for support. 4 - 50 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 119 6 Attach a lifting strap from an overhead crane or similar lifting device to the lifting eye at the rod end of the lift cylinder for support. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 51...
  • Page 120 Remove the lift cylinder from the machine. Crushing hazard. The lift cylinder may become unbalanced and fall when it is removed from the machine if not properly supported. 4 - 52 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 121: Rpm Adjustment

    Remove the air filter from the engine and lay it off to the side. 6 Close the shutoff valve on the Liquid Petroleum Gas (LPG) tank by turning it clockwise (if equipped). Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 53...
  • Page 122 Remove the flex plate from the flywheel. engine ECM is a sensitive instrument. It can be damaged internally if the ECM is dropped or sustains any physical shock, even if the damage is not visible. 4 - 54 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 123 Hoses can be damaged if they are kinked or pinched. 9 Remove the flex plate mounting fasteners. Remove the flex plate from the flywheel. Flex plate bolt torque sequence Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 55...
  • Page 124 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 - 56 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 125: Oil Temperature And Oil Pressure Switches - Deutz Models

    Oil pressure switch specifications engine tray roller wheels to prevent the engine tray from moving. Torque 8-10 ft-lbs 11-14 Nm Hex size inches Oil pressure switch point 7 psi 0.48 bar Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 57...

  • Page 126: Coolant Temperature And Oil Pressure Switches - Ford Models

    11-14 Nm tray from moving. Hex size inches 3 Locate the oil pressure or coolant temperature switch. Oil pressure switch point 8 psi 0.55 bar 4 - 58 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 127: Ground Controls

    Emergency Stop buttons to the on position at both platform and ground controls. Result: The revision level of the ECM will appear in the LED display window. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 59...
  • Page 128 11 Check the stowed drive speed of the machine. Refer to the Maintenance procedure B-15, Test the Drive Speed - Stowed Position . 4 - 60 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 129 9 Press the lift function enable button. the Drive Speed - Stowed Position . Result: is showing in the diagnostic TUNE SPEEDS display window. The ECM is now in programming mode. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 61...
  • Page 130 Pull out the red Emergency Stop button to the on position at the 10 Push in the red Emergency Stop button to the ground controls. off position at the ground controls. 4 - 62 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 131 9 Press the lift function enable button. Result: is showing in the diagnostic TUNE SPEEDS display window. The ECM is now in programming mode. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 63...
  • Page 132 Drive Speed - Raised Position . 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. 4 - 64 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 133 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. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 65...
  • Page 134 7 Press the lift function enable button. 11 Check the lift speed of the machine. Refer to Section 2, Specifications . 4 - 66 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 135 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 . Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 67...
  • Page 136 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. 4 - 68 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 137 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. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 69...

  • Page 138: Software Configuration (After Serial Number Gs9003-41522)

    Result: is showing in the SELECT OPTIONS yellow platform down button diagnostic display window. The ECM is now in programming mode. 4 - 70 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 139 Note: For this option to function correctly, the 14 Push in the red Emergency Stop button to the machine must be equipped with flashing beacons. off position at the ground controls. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 71...
  • Page 140 The ECM is now in motion beacons. programming mode. Result: is showing in the MOTION BEACONS diagnostic display window. 4 - 72 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 141 Press the lift function enable button to deactivate the sim operation option. Note: For CE models, the sim operation option should be deactivated or in the position. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 73...

  • Page 142: Level Sensor - Models Without Outriggers (Before Serial Number 41158)

    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. 4 - 74 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 143 28 Lower the machine onto the blocks. Level sensor - models without outriggers chassis level sensor "X" indicator "Y" indicator Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 75...
  • Page 144 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. 4 - 76 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 145: Level Sensor - Models Without Outriggers (After Serial Number 41157)

    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. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 77...
  • Page 146 17 Lower the platform to the stowed position. Level sensor - models without outriggers chassis level sensor "X" indicator "Y" indicator 4 - 78 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 147: Level Sensor - Models With Outriggers

    29 Raise the machine slightly. 3 Remove the ground control panel retaining 30 Remove the blocks from under both wheels. fasteners and open the panel. 31 Lower the machine and remove the jack. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 79...
  • Page 148 MODELS WITH OUTRIGGERS Level sensor - models without outriggers chassis level sensor "Y" indicator "X" indicator 4 - 80 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 149 3 seconds or until a beep is heard. 26 Push in the red Emergency Stop button to the off position at the platform controls. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 81...
  • Page 150 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. 4 - 82 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 151 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. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 83...

  • Page 152: Engine Fault Codes - Ford Models

    Do not start the engine. 4 Move and hold the run/test toggle switch to the test position. Result: The check engine light should turn on. The check engine light should begin to blink. 4 - 84 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 153 3 Connect the negative battery cable to the battery. 4 Start the engine and allow it to idle for approximately ten minutes. Result: The check engine light should not turn Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 85...

  • Page 154: Hydraulic Pumps

    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 - 86 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 155 Refer to Section 2, Specifications . 3 Release the latches on the engine tray and fully slide the engine tray out. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 87...

  • Page 156: 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 157: Manifolds

    Deutz models: Release the manual fuel shut-off lever. 6 Start the engine from the ground controls and check for hydraulic leaks. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 89...

  • Page 158: Function Manifold Components - Models With Outriggers (Before Serial Number 40519)

    3000 psi / 207 bar ......K ... Outrigger extend circuit ....... 35 ft-lbs / 47 Nm Counterbalance valve, 3000 psi / 207 bar ......L ... Outrigger retract circuit ....... 35 ft-lbs / 47 Nm 4 - 90 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 159 July 2007 Section 4 • Repair Procedures REV G MANIFOLDS Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 91...

  • Page 160: Function Manifold Components - Models With Outriggers (After Serial Number 40518)

    0.1 gpm / 0.38 L/min ......AJ ..Bleeds off proportional valve to tank ..........20 ft-lbs / 27 Nm DO3 valve, 3 position 4 way ..... AK ..Outrigger up/down ....... 30-35 in-lbs / 3-4 Nm 4 - 92 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 161 July 2007 Section 4 • Repair Procedures REV G MANIFOLDS Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 93...

  • Page 162: Function Manifold Components - Models Without Outriggers (Before Serial Number 40519)

    Proportional solenoid valve ....H ... All functions ..........30 ft-lbs / 47 Nm DO3 valve, 3 position 4 way ....I .... Platform up/down ......... 30-35 in-lbs / 3-4 Nm 4 - 94 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 163 July 2007 Section 4 • Repair Procedures REV G MANIFOLDS Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 95...

  • Page 164: Function Manifold Components - Models Without Outriggers (After Serial Number 40518)

    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 Nm 4 - 96 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 165 July 2007 Section 4 • Repair Procedures REV G MANIFOLDS Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 97...

  • Page 166: Drive Manifold Components (Before Serial Number Gs9004-41691)

    ..... 30 ft-lbs / 41 Nm Flow divider/combiner valve ....BQ ..Controls flow to flow divider/ combiner valves BO and BP in forward and reverse ........50 ft-lbs / 68 Nm 4 - 98 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 167 July 2007 Section 4 • Repair Procedures REV G MANIFOLDS Y49A Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 99...

  • Page 168: Drive Manifold Components (After Serial Number Gs9004-41690)

    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 - 100 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 169 July 2007 Section 4 • Repair Procedures REV G MANIFOLDS Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 101...

  • Page 170: Oscillate Manifold Components (Optional After Serial Number Gs9004-41690)

    Solenoid valve, 2 position 3 way ..DF ..Left oscillate circuit ........20 ft-lbs / 27 Nm Solenoid valve, 2 position 2 way ..DG ..Oscillate float ..........25 ft-lbs / 34 Nm 4 - 102 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 171 July 2007 Section 4 • Repair Procedures REV G MANIFOLDS Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 103...

  • Page 172: Valve Adjustments - Function Manifold

    After serial number GS9003-41522: Press Note: Perform this test from the ground with the and hold the lift function enable button. platform controls. Do not stand in the platform. 4 - 104 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 173 Install the relief valve cap. 19 Start the engine. 20 Repeat this procedure beginning with step 15. 21 Turn the machine off and remove the weight from the platform. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 105...

  • Page 174: 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 - 106 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 175 July 2007 Section 4 • Repair Procedures REV G MANIFOLDS This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 107...

  • Page 176: 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 - 108 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 177: Valve Adjustments - Generator Manifold

    Do not adjust the generator to other than specified. 9 Repeat steps 2 through 5 to confirm the generator AC voltage. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 109...

  • Page 178: Valve Coils

    10%, 12V DC with diode (schematic item DG) replace the coil. Solenoid valve, 2 position 3 way 6 to 8Ω 10V DC with diode (schematic items EF and EJ) 4 - 110 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 179 July 2007 Section 4 • Repair Procedures REV G 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 180: Fuel And Hydraulic Tanks

    Crushing hazard. Keep hands Note: Clean the fuel tank and inspect for cracks clear of the safety arm when and other damage before installing. lowering the platform. 4 - 112 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 181: Hydraulic Tank

    Lock the safety arm in from the key switch and tag the position. machine to inform personnel of the Note: Be sure that the safety arm is locked in the condition. vertical position. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 113...
  • Page 182 See 6-2, How to Prime the Pump. Note: Always use pipe thread sealant when installing the drain plug and strainers. 4 - 114 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 183: Steer Axle Components

    5 Remove the hose clamps retaining fasteners from the drive motor guard. Remove the hose clamps. 6 Remove the retaining fasteners from the drive motor guard. Remove the drive motor guard from the yoke. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 115...
  • Page 184 2 inches / 5 cm. Place blocks under the chassis for support. Crushing hazard. The chassis will fall if it is not properly supported. 4 Remove the wheel lug nuts. Remove the tire and wheel assembly. 4 - 116 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 185: Steer Cylinder

    Note: 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. 72863 GS-3390 • GS-4390 • GS-5390 4 - 117...

  • Page 186: Tie Rod

    13 Tighten the jam nut on the adjustable end of the to back, using a measuring fixture. tie rod. Toe-in specification Measurement 0 ± 0.125 inch 0 ± 3.2 mm 4 - 118 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 187: Oscillating Axle Option (After Serial Number Gs9004-41690)

    Terminal 86 of CR85 receives continuous power from pin J2-C6 when the ECM is powered until an outrigger is lowered to the ground, at which point the power from J2-C6 is cut. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 119...

  • Page 188: Non-Steer Axle Components

    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. 4 - 120 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 189: Drive Hub

    Torque specifications Drive hub mounting bolts, dry 120 ft-lbs 163 Nm Drive hub mounting bolts, lubricated 90 ft-lbs 122 Nm Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 121...

  • Page 190: 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 gradually. Do not allow oil to squirt or spray. 4 - 122 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 191: Platform Overload Components

    9 Raise the platform to approximately 6 m. 10 Release the safety arm latch, lift the safety arm and rotate to a vertical position. Lock the safety arm in position. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 123...
  • Page 192 (or adjustment screw) into the hydraulic line will deactivate the alarm. Note: Wait a minimum of 3 seconds between each quarter turn of the nut (or adjustment screw) to allow the platform overload system to reset. 4 - 124 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 193 Lower the platform to the stowed position. 65 cm less than full height. Note: After returning the safety arm to the stowed position, use the auxiliary down function to lower the platform. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 125...
  • Page 194 26. Securely platform overload system to reset. tighten the cam fasteners. Do not over tighten. 4 - 126 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 195 Perpendicular Result: The engine continues to run. Proceed to to cylinder step 34. Result: The engine has stopped and an alarm is sounding. Proceed to step 35. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 127...
  • Page 196 48 Release the safety arm latch, lift the safety arm will activate the alarm; turning the screw into the and rotate to a vertical position. Lock the safety hydraulic line will deactivate the alarm. arm in position. 4 - 128 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 197 52 Install and adjust the maximum height limit cycled after each adjustment. switch cam until the limit switch activates just before the point reached in step 51. Securely tighten the cam fasteners. Do not over tighten. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 129...
  • Page 198 73 Return the safety arm to the stowed position. Result: is showing in the DESCENT DELAY OFF 74 Raise the platform approximately 1 m. diagnostic display window. 75 Repeat this procedure beginning with step 68. 4 - 130 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 199 Proceed to step 99. Result: The platform stops lowering. The down limit switch needs to be calibrated. Proceed to step 95. 95 Raise the platform to approximately 6 m. Part No. 72863 GS-3390 • GS-4390 • GS-5390 4 - 131...
  • Page 200 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 4 - 132 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 201 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. 72863 GS-3390 • GS-4390 • GS-5390 5 - 1...
  • Page 202 The codes listed in the Fault Code Chart still exists describe malfunctions and can aid in troubleshooting the machine by pinpointing the Return to Inspect Perform service repair and test area or component affected. problem solved 5 - 2 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 203: Fault Code Chart (Before Serial Number Gs9003-41523)

    (Y49, Y49A) fault Function proportional coil Flash (Y9) fault Drive pump proportional coil Flash (Y51) fault Two speed coil (Y1) fault Flash Generator coil (Y29) fault Flash Continued on next page Part No. 72863 GS-3390 • GS-4390 • GS-5390 5 - 3...
  • Page 204 OR replace the oil temperature switch Low ECM voltage Battery discharged Charge battery Solid Engine idle RPM too low Low RPM Flash Consult Genie Industries Service Dept High RPM Engine RPM too high Flash 5 - 4 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 205: Fault Code Chart (After Serial Number Gs9003-41522)

    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. 72863 GS-3390 • GS-4390 • GS-5390 5 - 5...
  • Page 206 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-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 207 Drive reverse function disabled. Troubleshoot coil OR wiring. DRIVE REV PROP proportional coil (Y51) fault COIL FAULT Wrong machine type selected Machine will not operate. Correct selection. MACHINE TYPE FAULT Part No. 72863 GS-3390 • GS-4390 • GS-5390 5 - 7...

  • Page 208: Ford Engine Ecm Fault Code Chart (Before Serial Number Gs9003-41369)

    HO2 sensor to the connections OR HO2 sensor is bad. ECM to ground OR replace HO2 sensor. 5 - 8 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 209 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. 72863 GS-3390 • GS-4390 • GS-5390 5 - 9...

  • Page 210: Ford Engine Ecm Fault Code Chart (After Serial Number Gs9003-41368)

    Repair short in engine wire harness Adaptive Learn Low short to 5V DC or 12V DC OR fuel system OR test and repair the fuel system (LPG) components may be faulty. components. 5 - 10 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 211 OR replace sensor. Crankshaft position sensor wiring and/or connections open or shorted OR there is a poor Camshaft Sensor Loss system ground connection OR sensor is faulty. Part No. 72863 GS-3390 • GS-4390 • GS-5390 5 - 11...
  • Page 212 Repair VBAT power or ground circuit to ECM and MegaJector Voltage for 5 seconds anytime the engine is cranking or MegaJector OR replace battery OR repair Supply Low running. charging system OR replace the MegaJector. 5 - 12 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 213 Engine harness wiring and/or connections open Repair wiring and/or connections in engine Governor Interlock Failure or shorted OR there is a poor system ground harness OR replace the ECM. connection OR ECM is faulty. Part No. 72863 GS-3390 • GS-4390 • GS-5390 5 - 13...
  • Page 214 Locate and repair any engine harness wiring Loose wire connections to ECM OR ECM is faulty. damage or shorts to ECM to be sure they are secure OR replace ECM. RTI3 Loss 5 - 14 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 215 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 and test repair problem solved Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 1...

  • Page 216: Electronic Control Module Layout (Before Serial Number Gs9003-41523)

    (before serial number GS9003-41523) 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-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 217: A Electronic Control Module Pin-Out Legend

    Diagnostic Display G8 Right Rear Outrigger Coil Y34 Plug Diagnostic Display G8 Plug Plug Diagnostic Display G8 Ignition Relay CR8-86 Emergency Stop Relay CR41-87 Plug Plug Plug Plug Plug Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 3...

  • Page 218: Electronic Control Module Layout (After Serial Number Gs9003-41522)

    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-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 219: Electronic Control Module Pin-Out Legend (After Serial Number Gs9003-41522)

    Plug Engine Water Temp SW1 / Engine Oil Temp SW3 Plug (Input) Plug Aux Down Relay Cr23 Terminal 87 (output) Plug Flashing Beacons Fs1 (output) Plug ECM Power (input) Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 5...

  • Page 220: Ford Engine Relay Layout

    After serial number GS9003-41368 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-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 221: Wiring Diagram - Platform Control Box (Before Serial Number Gs9003-41523)

    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. 72863 GS-3390 • GS-4390 • GS-5390 6 - 7...

  • Page 222: Wiring Diagram - Platform Control Box (After Serial Number Gs9003-41522)

    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-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 223: Electrical Schematics Abbreviation And Wire Color Legends

    Ford circuit number, color and wire gauge BLUE GREY 2. Wires in the DSG423 engine schematic are labeled with BLACK ORANGE WHITE color and wire gauge. BROWN PURPLE YELLOW 3. Internal splices are not shown. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 9...

  • Page 224: Limit Switch Legend

    • left rear LS14A maximum height LS24 • right rear LS15A (CE models) (ground controls side) oscillate axle (GS-90 models) • left axle LS23 • right axle LS22 (located inside axle) 6 - 10 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 225 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 11...

  • Page 226: Electrical Symbols Legend

    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 - 12 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 227: A Electrical Schematic - Platform Overload (Option)

    LOAD SENSE SWITCH HEIGHT DELAY CR27 LIMIT LIMIT OVERLOAD SWITCH SWITCH CR42 POWER 4700 uF GROUND - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7167B Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 13...

  • Page 228: Wiring Harness - Ford Lrg-425 Efi (Before Serial Number Gs9003-41369)

    NOTE: * SHOWS USED WIRES MATING FACE SHOWN OIL PRESSURE SWITCH (NC) ENGINE HEATED COOLANT OXYGEN TEMPERATURE COIL MANIFOLD SENSOR SENSOR ABSOLUTE (HO2S) (ECT) PRESSURE SENSOR (MAP) LOCKOUT VALVE ES7144A 6 - 14 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 229: Wiring Harness - Ford Lrg-425 Efi (From Serial Number Gs9003-41369 To Gs9004-41693)

    GROUND MATING FACE 242DG18 DRYFUEL LOCKOFF SHOWN 96T/O18 IGNITION COIL 2 74GY/LB18 HO2S SENSOR SIDE DIAGNOSTIC (LOCATED INSIDE THE CONNECTOR GROUND CONTROL BOX) INTAKE AIR TEMPERATURE SENSOR (IAT) ES7144A Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 15...

  • Page 230: Wiring Harness - Ford Lrg-425 Efi (After Serial Number Gs9004-41693)

    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 - 16 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 231 461 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. 72863 GS-3390 • GS-4390 • GS-5390 6 - 17...
  • Page 232 669 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 - 18 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 233 570 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. 72863 GS-3390 • GS-4390 • GS-5390 6 - 19...

  • Page 234: Electrical Schematic - Ford Models (Before Serial Number 40428)

    J4-A5 FUSE TS69 LINK AUXILIARY 510 W FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN STARTER PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138G 6 - 20 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 235 N.C. 2 AXIS LEVEL SENSOR TILT LEVEL CIRCUIT BOARD SENSOR LEVEL SENSOR MODELS WITHOUT OUTRIGGERS - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138G Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 21...
  • Page 236 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-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 237 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 23...

  • Page 238: Electrical Schematic - Ford Models (From Serial Number 40428 To 40793)

    ELECTRONIC CONTROL MODULE J4-A5 FUSE TS69 LINK AUXILIARY 510 W FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN STARTER PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 - 24 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 239 Y49A N.C. 2 AXIS LEVEL SENSOR TILT LEVEL CIRCUIT BOARD SENSOR LEVEL SENSOR MODELS WITHOUT OUTRIGGERS - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 25...
  • Page 240 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-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 241 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 27...

  • Page 242: Electrical Schematic - Ford Models (From Serial Number 40794 To 40995)

    J4-A5 TS69 FUSE AUXILIARY LINK FUNCTION ENABLE 510 W TS70 AUXILIARY PLATFORM DOWN STARTER PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138H 6 - 28 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 243 N.C. 2 AXIS LEVEL SENSOR TILT LEVEL CIRCUIT BOARD SENSOR LEVEL SENSOR MODELS WITHOUT OUTRIGGERS - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138H Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 29...
  • Page 244 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-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 245 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 31...

  • Page 246: Electrical Schematic - Ford Models (From Serial Number 40996 To 41065)

    ELECTRONIC CONTROL MODULE FUSE LINK 510 W TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN STARTER PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138K 6 - 32 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 247 N.C. 2 AXIS LEVEL SENSOR TILT LEVEL CIRCUIT BOARD SENSOR LEVEL SENSOR MODELS WITHOUT OUTRIGGERS - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138K Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 33...
  • Page 248 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 - 34 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 249 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 35...
  • Page 250 J1-C11,C12 FUSE LINK 510 W TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN STARTER PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138K 6 - 36 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 251 N.C. 2 AXIS LEVEL SENSOR TILT LEVEL CIRCUIT BOARD SENSOR LEVEL SENSOR MODELS WITHOUT OUTRIGGERS - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138K Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 37...
  • Page 252 LIFT ENABLE LOW BN13 PIN4 DOWN PIN3 PLATFORM & OUTRIGGER POUT1 PIN4 UP/DOWN TS21 DOWN POUT1 ALARM PIN11 ALARM PIN11 PLATFORM CONTROLS PLATFORM CONTROLS (GASOLINE/LPG MODELS WITHOUT OUTRIGGERS) (GASOLINE/LPG MODELS WITH OUTRIGGERS) 6 - 38 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 253 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 39...
  • Page 254 J1-C11,C12 FUSE LINK 510 W TS69 AUXILIARY FUNCTION ENABLE TS70 AUXILIARY PLATFORM DOWN STARTER PUMP - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138L 6 - 40 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 255 N.C. 2 AXIS LEVEL SENSOR TILT LEVEL CIRCUIT BOARD SENSOR LEVEL SENSOR MODELS WITHOUT OUTRIGGERS - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES0138L Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 41...
  • Page 256 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 - 42 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 257 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 43...

  • Page 258: (From Serial Number Gs9003-41523 To Gs9004-41693)

    FORD ENGINE HARNESS STARTER PUMP FUEL PUMP OSCILLATING AXLE (OPTION) (AVAILABLE AFTER SERIAL NUMBER 41618) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163B 6 - 44 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 259 AUXILIARY DOWN ENABLE J2-C10 J2-B9 J1-B12 AB12 Y49A Y49 AND Y49A WERE REMOVED AFTER SERIAL NUMBER 41618 - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163B Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 45...
  • Page 260 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 - 46 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 261 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 47...

  • Page 262: (From Serial Number Gs9004-41694 To Gs9005-42143)

    FORD ENGINE HARNESS STARTER PUMP FUEL PUMP OSCILLATING AXLE (OPTION) (AVAILABLE AFTER SERIAL NUMBER 41618) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163C 6 - 48 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 263 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. 72863 GS-3390 • GS-4390 • GS-5390 6 - 49...
  • Page 264 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 - 50 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 265 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 51...

  • Page 266: (From Serial Number Gs9005-42144 To Gs9005-42203)

    FORD ENGINE HARNESS STARTER PUMP FUEL PUMP OSCILLATING AXLE (OPTION) (AVAILABLE AFTER SERIAL NUMBER 41618) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163E 6 - 52 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 267 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. 72863 GS-3390 • GS-4390 • GS-5390 6 - 53...
  • Page 268 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 - 54 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 269 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 55...

  • Page 270: (From Serial Number Gs9005-42204 To Gs9005-42685)

    FORD ENGINE HARNESS STARTER PUMP FUEL PUMP OSCILLATING AXLE (OPTION) (AVAILABLE AFTER SERIAL NUMBER 41618) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7163F 6 - 56 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 271 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. 72863 GS-3390 • GS-4390 • GS-5390 6 - 57...
  • Page 272 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 - 58 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 273 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 59...

  • Page 274: (From Serial Number Gs9003-41523 To Gs9004-41693)

    Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV D (from serial number GS9003-41523 to GS9004-41693) Part 1 of 3 6 - 60 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 275 June 2008 Section 6 • Schematics Electrical Schematic CE Models with Ford Power REV D (from serial number GS9003-41523 to GS9004-41693) Part 2 of 3 Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 61...
  • Page 276 Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV D (from serial number GS9003-41523 to GS9004-41693) Part 3 of 3 6 - 62 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 277 June 2008 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 63...

  • Page 278: (From Serial Number Gs9004-41694 To Gs9005-42143)

    Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV D (from serial number GS9004-41694 to GS9005-42143) Part 1 of 3 6 - 64 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 279 June 2008 Section 6 • Schematics Electrical Schematic CE Models with Ford Power REV D (from serial number GS9004-41694 to GS9005-42143) Part 2 of 3 Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 65...
  • Page 280 Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV D (from serial number GS9004-41694 to GS9005-42143) Part 3 of 3 6 - 66 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 281 June 2008 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 67...
  • Page 282 Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV D (from serial number GS9005-42144 to GS9005-42203) Part 1 of 3 6 - 68 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 283 June 2008 Section 6 • Schematics Electrical Schematic CE Models with Ford Power REV D (from serial number GS9005-42144 to GS9005-42203) Part 2 of 3 Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 69...
  • Page 284 Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV D (from serial number GS9005-42144 to GS9005-42203) Part 3 of 3 6 - 70 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 285 June 2008 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 71...
  • Page 286 Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV C (from serial number GS9005-42204 to GS9005-42411) Part 1 of 3 6 - 72 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 287 June 2008 Section 6 • Schematics Electrical Schematic CE Models with Ford Power REV C (from serial number GS9005-42204 to GS9005-42411) Part 2 of 3 Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 73...
  • Page 288 Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV C (from serial number GS9005-42204 to GS9005-42411) Part 3 of 3 6 - 74 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 289 June 2008 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 75...

  • Page 290: (From Serial Number Gs9005-42412 To Gs9005-42685)

    Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV C (from serial number GS9005-42412 to GS9005-42685) Part 1 of 3 6 - 76 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 291 June 2008 Section 6 • Schematics Electrical Schematic CE Models with Ford Power REV C (from serial number GS9005-42412 to GS9005-42685) Part 2 of 3 Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 77...
  • Page 292 Section 6 • Schematics June 2008 Electrical Schematic CE Models with Ford Power REV C (from serial number GS9005-42412 to GS9005-42685) Part 3 of 3 6 - 78 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 293 June 2008 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 79...

  • Page 294: Electrical Schematic - Deutz Models (Before Serial Number 40428)

    TS70 SOLENOID AUXILIARY CONTROL PLATFORM DOWN MODULE STARTER GLOW PUMP PLUG FUEL (OPTION) SHUT OFF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142A 6 - 80 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 295 DISPLAY SWITCH SWITCH SWITCH (GS-5390) (OPTION) ELECTRONIC CONTROL MODULE Y49A 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142A Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 81...
  • Page 296 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-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 297 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 83...
  • Page 298 STARTING TS70 SOLENOID AUXILIARY CONTROL PLATFORM DOWN MODULE STARTER GLOW PUMP PLUG FUEL (OPTION) SHUT OFF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF 6 - 84 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 299 PRESSURE DISPLAY SWITCH SWITCH SWITCH (GS-5390) (OPTION) ELECTRONIC CONTROL MODULE Y49A 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 85...
  • Page 300 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-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 301 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 87...
  • Page 302 TS70 SOLENOID AUXILIARY CONTROL PLATFORM DOWN MODULE STARTER GLOW PUMP PLUG FUEL (OPTION) SHUT OFF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142B 6 - 88 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 303 DISPLAY SWITCH SWITCH SWITCH (GS-5390) (OPTION) ELECTRONIC CONTROL MODULE Y49A 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142B Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 89...
  • Page 304 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 - 90 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 305 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 91...
  • Page 306 AUXILIARY PLATFORM DOWN 15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142C 6 - 92 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 307 DISPLAY SWITCH SWITCH SWITCH (GS-5390) (OPTION) ELECTRONIC CONTROL MODULE Y49A 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142C Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 93...
  • Page 308 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 - 94 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 309 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 95...
  • Page 310 AUXILIARY PLATFORM DOWN 15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142D 6 - 96 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 311 DISPLAY SWITCH SWITCH SWITCH (GS-5390) (OPTION) ELECTRONIC CONTROL MODULE Y49A 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142D Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 97...
  • Page 312 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 - 98 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 313 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 99...
  • Page 314 AUXILIARY PLATFORM DOWN 15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142E 6 - 100 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 315 DISPLAY SWITCH SWITCH SWITCH (GS-5390) (OPTION) ELECTRONIC CONTROL MODULE Y49A 2 AXIS TILT LEVEL SENSOR - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7142E Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 101...
  • Page 316 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 - 102 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 317 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 103...

  • Page 318: (From Serial Number Gs9003-41523 To Gs9005-42143)

    FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID OSCILLATING AXLE (OPTION) (AVAILABLE AFTER SERIAL NUMBER 41618) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164C 6 - 104 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 319: (From Serial Number Gs9003-41523 To Gs9005-42143)

    AUXILIARY DOWN ENABLE J2-C4 J2-C10 J2-B9 AB12 Y49A Y49 AND Y49A WERE REMOVED AFTER SERIAL NUMBER 41618 - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164C Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 105...
  • Page 320 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 - 106 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 321 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 107...
  • Page 322 15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID OSCILLATING AXLE (OPTION) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7164G 6 - 108 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 323 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. 72863 GS-3390 • GS-4390 • GS-5390 6 - 109...
  • Page 324 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 - 110 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 325 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 111...
  • Page 326 FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID OSCILLATING AXLE (OPTION) (AVAILABLE AFTER SERIAL NUMBER 41618) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175A 6 - 112 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 327 B10 BECOMES AB11 ON GS-5390 4700 uF Y49 AND Y49A WERE REMOVED AFTER SERIAL NUMBER 41618 - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175A Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 113...
  • Page 328 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 - 114 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 329 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 115...
  • Page 330 15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID OSCILLATING AXLE (OPTION) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175F 6 - 116 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 331 LIMIT ENABLE SWITCH AB14 IF GS-5390, NOT USED B10 BECOMES AB11 ON GS-5390 4700 uF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175F Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 117...
  • Page 332 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 ES7175F 6 - 118 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 333 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 119...

  • Page 334: (From Serial Number Gs9005-42412 To Gs9005-42685)

    15A FUSE GLOW PUMP PLUG FUEL (OPTION) SHUT OFF HIGH IDLE SOLENOID OSCILLATING AXLE (OPTION) - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175K 6 - 120 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 335 LIMIT ENABLE SWITCH AB14 IF GS-5390, NOT USED B10 BECOMES AB11 ON GS-5390 4700 uF - NOTE - MACHINE SHOWN IN THE STOWED POSITION WITH THE POWER OFF ES7175K Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 121...
  • Page 336 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 - 122 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 337 July 2007 Section 6 • Schematics This page intentionally left blank. Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 123...

  • Page 338: Hydraulic Schematics Component Call-Out Legend

    Controls fluid flow to flow side to side at the steer end divider/combiner valves BO and BP in Orifice, controls flow front to rear forward and reverse Test port #1 6 - 124 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 339: Hydraulic Symbols Legend

    3 position 4 way valve directional valve Y49A Solenoid operated Flow Solenoid operated 2 position 3 way divider/combiner 2 position 2 way directional valve valve directional valve Part No. 72863 GS-3390 • GS-4390 • GS-5390 6 - 125...
  • Page 340 0 to 30 gpm 40.9 L/min 24.6 L/min 0 to 113.6 L/min 3625 psi COOLER 250 bar (OPTION) 360 psi DRIVE PUMP 24.8 bar 25 psi 1.7 bar HYDRAULIC TANK HS7036C 6 - 126 GS-3390 • GS-4390 • GS-5390 Part No. 72863...

  • Page 341: Hydraulic Schematic (Before Serial Number 40519)

    REAR GS-4390 and GS-5390 Left Right 2900 psi 2900 psi 200 bar 200 bar GS-3390: 1800 psi / 124 bar GS-4390: 1800 psi / 124 bar GS-5390: 1100 psi / 76 bar LEV1 LEV2 3000 psi 3000 psi 10 psi...

  • Page 342: Hydraulic Schematic (From Serial Number Gs9004-41691 To Gs9005-42685)

    0 to 30 gpm 40.9 L/min 24.6 L/min 0 to 113.6 L/min 3625 psi COOLER 250 bar (OPTION) 360 psi DRIVE PUMP 24.8 bar 25 psi 1.7 bar HYDRAULIC TANK HS7036C 6 - 128 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 343 (OPTION) RIGHT LEFT RIGHT LEFT FRONT FRONT REAR REAR STEER CYLINDERS GS-3390: 1800 psi / 124 bar GS-4390: 1800 psi / 124 bar GS-5390: 1100 psi / 76 bar LEFT RIGHT LEV1 LEV2 0.150 in 3.8 mm 2000 psi 138 bar 0.1 gpm...
  • Page 344 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 - 130 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 345 REAR REAR 3800 psi 3800 psi 262 bar 262 bar 4.5:1 4.5:1 STEER CYLINDERS GS-3390: 1800 psi / 124 bar GS-4390: 1800 psi / 124 bar GS-5390: 1100 psi / 76 bar LEFT RIGHT LEV1 LEV2 900 psi 62 bar 0.150 in...
  • Page 346 Section 6 • Schematics July 2007 This page intentionally left blank. 6 - 132 GS-3390 • GS-4390 • GS-5390 Part No. 72863...
  • Page 347 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 575100 Fax +...

This manual is also suitable for:

Gs-4390Gs-5390

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