Page 1 Service and Repair Manual Serial Number Range -3384 ™ from GS8413-42181 This manual includes: to GS8415-42382 Repair procedures from GS8416F-42383 -3390 ™ to GS8416F-45499 Fault Codes from GS84F-45500 Electrical and to GS84F-45999 -4390 ™ from GS84D-101 Hydraulic Schematics to GS84D-400 -5390 ™...
Page 2 Group A/Type 2, 3 as defined by ISO 16368 First Edition, Second Printing Machine Design Life Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. Unrestricted with proper operation, inspection and “GS” is a trademark of Terex South Dakota, Inc.
Page 3 June 2021 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 3/2016 Initial Release 9/2016 Introduction Serial Number Legend 5/2017 Specifications Machine Specifications 8/2020 Cover Add ending serial break Repair Engine Fault Codes Schematics Electrical schematics 6/2021 Repair...
Page 4: Introduction
Service and Repair Manual June 2021 Introduction Serial Number Legend To August 31, 2016 1 Model 4 Sequence number 2 Model year 5 Serial label (located inside cover) 3 Facility code 6 Serial number (stamped on chassis) From September 1, 2016 1 Model 4 Serial label (located inside cover) 2 Facility code...
Page 5: Safety Rules
June 2021 Service and Repair Manual Safety Rules Section 1 Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are performed.
Page 6 Service and Repair Manual June 2021 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine Any person working on or around a machine must be aware of all known safety hazards. must be aware of all known safety hazards. Personal safety and the continued safe Personal safety and the continued safe operation of the machine should be your top...
Page 7: Table Of Contents
June 2021 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Revision History ..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications ....................... 1 Machine Specifications ................... 1 Performance Specifications ..................
Page 8 June 2021 Table of Contents Section 3 Repair Procedures ..................... 15 Introduction ......................15 Platform Controls ....................17 1-1 Circuit Board ....................17 How to Remove the Platform Controls Circuit Board ........17 Platform Components ..................18 2-1 Platform ......................18 How to Remove the Platform ................
Page 9 June 2021 Table of Contents Engines ........................ 48 4-1 RPM Adjustment .................... 48 4-2 Flex Plate ....................... 48 How to Remove the Flex Plate - Ford Models ..........48 How to Remove the Flex Plate - Deutz Models ..........49 How to Install the Flex Plate ................
Page 10 June 2021 Table of Contents Hydraulic Pump ....................72 6-1 Lift/Steer Pump ....................72 How to Remove the Lift/Steer Pump .............. 72 6-2 Drive Pump ....................73 How to Remove the Drive Pump ..............73 How to Prime the Pump .................. 74 How to Adjust the Pump Neutral..............
Page 11 June 2021 Table of Contents Fuel and Hydraulic Tanks .................. 94 8-1 Fuel Tank ....................... 94 8-2 Hydraulic Tank ....................95 Steer Axle Components ..................97 9-1 Yoke Assembly ....................97 How to Remove the Yoke and Drive Motor ............. 97 How to Remove a Drive Motor ................
Page 12 June 2021 Table of Contents Section 4 Fault Codes ....................... 116 Introduction ......................116 Control System Fault Codes ................118 Fault Code Display - Deutz Models ..............122 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 Models ... 122 Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 Models ..
Page 13 June 2021 Table of Contents Electrical Schematics - Engine Harness ............157 Ford MSG-425 EFI Engine Wire Harness ............158 Deutx D 2.9 L4 Engine Wire Harness ..............159 Hydraulic Schematics ..................161 Hydraulic Schematic, To Serial Numbers GS8415-42316 and GS9015-50184 ......162 Hydraulic Schematic, From Serial Numbers GS84154-42317 and GS9015-50185 .....
Page 14 June 2021 Table of Contents Electrical Schematics – AS and CE Models ..........183 Electrical Schematic, Ford Engine Models (AS/CE) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948) ..184 Electrical Schematic, Ford Engine Models (AS/CE) (from GS84F-54672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081) ................
Page 15: Specifications
June 2021 Service and Repair Manual Specifications Section 2 Specifications Machine Specifications Rough Terrain, foam-filled (GS-90) Tire size LSW 305-546 NHS Fluid capacities Tire ply rating Hydraulic tank 30 gallons Tire weight, new foam-filled 265 lbs 114 liters (minimum) (Rough terrain) 120 kg Hydraulic system (including tank) 37.5 gallons...
Page 16: Performance Specifications
Service and Repair Manual June 2021 Specifications Performance Specifications Function speed, maximum from platform controls (with maximum rated load in platform) Drive speed, maximum (GS-90) GS-3384 and GS-3390 Platform stowed 5 mph Platform up 40 to 50 seconds 40 ft / 5.5 sec Platform down 24 to 34 seconds 8 km/h...
Page 17: Hydraulic Oil Specifications
June 2021 Service and Repair Manual Specifications Hydraulic Oil Specifications Do not top off with incompatible hydraulic fluids. Hydraulic fluids may be incompatible due to the Hydraulic Fluid Specifications differences in base additive Genie specifications require hydraulic oils which are chemistry.
Page 18 Service and Repair Manual June 2021 Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 200°F / 100°C 15.0 cSt @ 104°F / 40°C 33.5...
Page 19 June 2021 Service and Repair Manual Specifications Petro-Canada Environ MV 46 UCON Hydrolube HP-5046 Fluid Fluid Properties Properties ISO Grade ISO Grade Viscosity index Viscosity index Kinematic Viscosity Kinematic Viscosity cSt @ 200°F / 100°C cSt @ 149°F / 65°C cSt @ 104°F / 40°C 44.4 cSt @ 104°F / 40°C...
Page 20: Hydraulic Component Specifications
Service and Repair Manual June 2021 Specifications Hydraulic Component Function manifold Specifications System relief valve pressure, 2700 to 2900 psi maximum, GS-3384 and GS-3390 186 to 200 bar Drive Pump System relief valve pressure, 2900 to 3100 psi maximum, GS-4390 and GS-5390 200 to 214 bar Type: bi-directional variable displacement piston pump Steer relief valve pressure, GS-...
Page 21: Manifold Component Specifications
June 2021 Service and Repair Manual Specifications Manifold Component Oscillate manifold (GS-90) (option) Specifications System relief valve pressure, 3500 psi maximum 241 bar Plug torque Float relief valve pressure 900 psi 62 bar SAE No. 2 36 in-lbs / 4 Nm Oscillate flow regulator 1 gpm SAE No.
Page 22: Ford Msg-425 Efi Engine Specifications
Service and Repair Manual June 2021 Specifications Ford MSG-425 EFI Engine Electronic fuel pump Fuel pressure, static 60 psi Displacement 153 cu in 4.1 bar 2.5 liters Fuel flow rate 0.43 gpm Number of cylinders 1.6 L/min Bore and Stroke 3.5 x 3.9 inches Fuel requirement 89 x 100 mm...
Page 23: Deutz D2011 L03I Engine Specifications
June 2021 Service and Repair Manual Specifications Deutz D2011 L03i Engine Lubrication system Oil pressure 20 to 44 psi Displacement 142 cu in 1.4 to 3 bar 2.33 liters Oil capacity (including filter) 9.5 quarts Number of cylinders 9 liters Bore and Stroke 3.7 x 4.4 inches Oil capacity (including filter)
Page 24: Deutz D 2.9 L4 Engine Specifications
Service and Repair Manual June 2021 Specifications Deutz D 2.9 L4 Engine Oil viscosity requirements Low ash oil required -22° F to 86° F/ -30° C to 30° C 5W-30 (synthetic) Displacement 177 cu in -4° F to 90° F / -20° C to 32° C 10W-40 2.9 liters Above 23°...
Page 25 June 2021 Service and Repair Manual Specifications Deutz D 2.9 L4 Engine, continued Starter motor Current draw, normal load 250A to 400A Brush length, new 0.72 in 18.5 mm Brush length, minimum 0.27 in 7 mm Battery Type 12V DC Quantity Cold cranking ampere 1000A...
Page 26: Hydraulic Hose And Fitting Torque Specifications
Service and Repair Manual June 2021 Specifications Hydraulic Hose and Fitting SAE O-ring Boss Port Torque Specifications (tube fitting - installed into Aluminum) (all types) Your machine is equipped with Parker Seal-Lok™ SAE Dash Size Torque ORFS or 37° JIC fittings and hose ends. Genie 14 ft-lbs / 19 Nm specifications require that fittings and hose ends be torqued to specification when they are removed...
Page 27: Torque Procedure
June 2021 Service and Repair Manual Specifications Torque Procedure JIC 37° fittings Align the tube flare (hex nut) against the nose Seal-Lok™ fittings of the fitting body (body hex fitting) and tighten the hex nut to the body hex fitting to Replace the O-ring.
Page 28 Service and Repair Manual June 2021 Specifications Working clockwise on the body hex fitting, make a second mark with a permanent ink marker to indicate the proper tightening position. Refer to Illustration 2. Note: Use the JIC 37° Fitting table in this section to determine the correct number of flats, for the proper tightening position.
Page 29: Repair Procedures
June 2021 Service and Repair Manual Repair Procedures Machine Configuration: Section 3 Repair Procedures  Unless otherwise specified, perform each repair procedure with the machine in the following configuration: • Machine parked on a firm, level surface • Key switch in the off position with the key Observe and Obey: removed Repair procedures shall be completed by a...
Page 30 Service and Repair Manual June 2021 Repair Procedures About This Section Symbols Legend Safety alert symbol—used to alert Most of the procedures in this section should only personnel to potential personal be performed by trained service professional in a injury hazards. Obey all safety suitably equipped workshop.
Page 31: Platform Controls
June 2021 Service and Repair Manual Platform Controls Platform controls Circuit Board The platform controls, used to activate machine How to Remove the Platform Controls Circuit Board functions from the platform or while standing on How to Remove the Platform the ground, contain a printed circuit board, joystick, decal membrane pad, buttons and LEDs.
Page 32: Platform Components
Service and Repair Manual June 2021 Platform Components Cut the zip ties that secure the power to platform wiring to the bottom of the platform. Platform Component damage hazard. Be How to Remove the Platform sure not to cut the power to platform wiring.
Page 33 June 2021 Service and Repair Manual Platform Components Note: If your machine is equipped with an air line 21 Remove the pin retaining fasteners from each to platform option, the air line must be platform slider block pivot pin. Do not remove disconnected from the platform before removal.
Page 34: Platform Extension Deck
Service and Repair Manual June 2021 Platform Components Carefully slide the platform extension deck out until the platform extension deck makes Platform Extension Deck contact with the carriage on the forklift. How to Remove the Platform Extension Deck Attach a strap from the platform extension deck railings to the carriage on the forklift to How to Remove the Platform help support the platform extension deck.
Page 35: Scissor Components
June 2021 Service and Repair Manual Scissor Components Non-steer End Steer End 1 Platform centering link 11 Number 3 outer arm 2 Number 3 inner arm 12 Lift cylinder rod-end pivot pin 3 Number 3 center pivot pin (Qty. 2) 13 Number 3 pivot pin (steer end) 4 Number 3 pivot pin (non-steer end) 14 Number 2 center pivot pin (Qty.
Page 36: Scissor Assembly, Gs-3384 And Gs-3390
Service and Repair Manual June 2021 Scissor Components Use a soft metal drift to remove the lift cylinder rod-end pivot pin (index #12). Lower Scissor Assembly, GS-3384 and the rod end of the lift cylinder down onto the 3390 number 2 inner arm (index #6). Crushing hazard.
Page 37 June 2021 Service and Repair Manual Scissor Components 10 Place a rod through the cable tray pivot pin 17 Use a slide hammer to remove both number and twist to remove the pin. Lower the cable 3 pivot pins (index #13) from the steer end of tray down.
Page 38 Service and Repair Manual June 2021 Scissor Components 25 Lower the number 1 outer arm (index #16) 36 Place a rod through the cable tray pivot pin onto the block. and twist to remove the pin. Lower the cable tray onto the number 1 inner arm (index #8). Crushing hazard.
Page 39 June 2021 Service and Repair Manual Scissor Components 44 Carefully remove the number 2 inner and 52 Use a slide hammer to remove the number outer arms (index #5 and #6) from the 1 inner arm slide block pivot pins (index #19). machine.
Page 40: How To Disassemble A Scissor Arm Pair
Service and Repair Manual June 2021 Scissor Components How to Disassemble a Scissor How to Disassemble a Scissor Arm Pair Place a 12 inch / 30 cm block under the center of the scissor arm pair. Lower the Arm Pair scissor arm pair onto the block.
Page 41 June 2021 Service and Repair Manual Scissor Components Non-steer End Steer End 1 Platform centering link 13 Number 1 pivot pins (non-steer end) 2 Number 4 outer arm 14 Number 4 inner arm 3 Number 4 center pivot pin (Qty. 2) 15 Number 4 pivot pin (steer end) 4 Number 4 pivot pin (non-steer end) 16 Number 3 outer arm...
Page 42: Scissor Assembly, Gs-4390
Service and Repair Manual June 2021 Scissor Components Attach a lifting strap from an overhead crane to the number 4 inner and outer arms (index Scissor Assembly, GS-4390 #14 and #2) at the non-steer end of the machine. Do not apply any lifting pressure. How to Disassemble the Scissor Assembly Remove the pin retaining fasteners from both How to Disassemble the Scissor...
Page 43 June 2021 Service and Repair Manual Scissor Components 22 Remove the pin retaining fasteners from the 14 Use a soft metal drift to remove the lift cable tray pivot pin at the number 3 inner arm. cylinder rod-end pivot pin (index #17). Lower the rod end of the lift cylinder down.
Page 44 Service and Repair Manual June 2021 Scissor Components 28 Remove the pin retaining fasteners from both 36 Carefully lift the number 1 outer arm at the number 3 pivot pins (index #19) at the steer non-steer end approximately 15 inches / end of the machine.
Page 45 June 2021 Service and Repair Manual Scissor Components 46 Remove the strap installed in step 32. 53 Remove the pin retaining fasteners from both number 2 pivot pins (index #9) at the non- 47 Support the cable tray with an overhead steer end of the machine.
Page 46: How To Disassemble A Scissor Arm Pair
Service and Repair Manual June 2021 Scissor Components How to Disassemble a Scissor How to Disassemble a Scissor Arm Pair 61 Attach a lifting strap from an overhead crane to the number 1 inner and outer arms (index Arm Pair #10 and #12) at the non-steer end of the machine.
Page 47 June 2021 Service and Repair Manual Scissor Components Place a 12 inch / 30 cm block under the center of the scissor arm pair. Lower the scissor arm pair onto the block. Remove the external snap rings from both center pivot pins. Use a soft metal drift to remove both center pins.
Page 48 Service and Repair Manual June 2021 Scissor Components Non-steer End Steer End 1 Platform centering link 16 Number 1 outer arm 2 Number 5 inner arm 17 Number 1 pivot pins (non-steer end) 3 Number 5 center pivot pin (Qty. 2) 18 Number 5 outer arm 4 Number 5 pivot pin (non-steer end) 19 Number 5 pivot pin (steer end)
Page 49: Scissor Assembly, Gs-5390
June 2021 Service and Repair Manual Scissor Components Attach a lifting strap from an overhead crane to the number 5 inner and outer arms (index Scissor Assembly, GS-5390 #2 and #18) at the steer end of the machine. Do not apply any lifting pressure. How to Disassemble the Scissor Assembly Attach a lifting strap from an overhead crane How to Disassemble the Scissor...
Page 50 Service and Repair Manual June 2021 Scissor Components 14 Use a soft metal drift to remove the upper lift 23 Support the rod end of the upper lift cylinder cylinder rod-end pivot pin (index #21). Lower with a suitable lifting device. the rod end of the upper lift cylinder down.
Page 51 June 2021 Service and Repair Manual Scissor Components 36 Secure both ends of the number 3 inner and 30 Carefully lower the rod end of the lower lift outer arms (index #8 and #23) together with a cylinder onto the engine cover. strap or other suitable device.
Page 52 Service and Repair Manual June 2021 Scissor Components 44 Secure the non-steer end of the number 54 Carefully remove the lift cylinder from the 2 inner and outer arms (index #26 and #27) machine. and the non-steer end of the number 1 inner Crushing hazard.
Page 53 June 2021 Service and Repair Manual Scissor Components 61 Place a rod through the cable tray pivot pin 67 Use a slide hammer to remove both number and twist to remove the pin. Lower the cable 2 pivot pins (index #13) from the non-steer tray onto the number 1 inner arm (index #14).
Page 54: How To Disassemble A Scissor Arm Pair
Service and Repair Manual June 2021 Scissor Components How to Disassemble a Scissor How to Disassemble a Scissor Arm Pair 75 Place a rod through each chassis centering link pivot pin and twist to remove the pin. Rest Arm Pair the centering links on the chassis.
Page 55: Wear Pads
June 2021 Service and Repair Manual Scissor Components Place a 12 inch / 30 cm block under the center of the scissor arm pair. Lower the Wear Pads scissor arm pair onto the block. How to Replace the Scissor Arm Wear Pad How to Replace the Platform Remove the external snap rings from both center pivot pins.
Page 56: How To Replace The Chassis Scissor Arm Wear Pads
Service and Repair Manual June 2021 Scissor Components How to Replace the Chassis How to Replace the Chassis Scissor Arm Wear Pads Remove the pin retaining fasteners from each platform slide block pivot pin. Do not remove Scissor Arm Wear Pads the pins.
Page 57 June 2021 Service and Repair Manual Scissor Components Remove the retaining fasteners from the top 17 Install the new wear pads onto the scissor engine cover plate. Remove the plate from arm slide blocks. the machine. 18 Install the slide blocks onto the chassis. Loosen the retaining fasteners from each side 19 Align the holes in the slide blocks with the engine cover plate.
Page 58: Lift Cylinders
Service and Repair Manual June 2021 Scissor Components Start the engine from the ground controls and raise the platform approximately 18 feet / Lift Cylinders 5.5 m from the ground. The lift cylinders are double acting hydraulic Release the safety arm latch, lift the safety cylinders.
Page 59 June 2021 Service and Repair Manual Scissor Components Cut the zip ties attaching the hydraulic hoses 11 Remove the lift cylinder barrel-end pivot pin to the lift cylinder. Lay the hoses out of the retaining fastener. Use a soft metal drift to way.
Page 60: How To Remove The Lift Cylinder - Gs-5390
Service and Repair Manual June 2021 Scissor Components How to Remove the Lift Cylinder - How to Remove the Lift Cylinder - GS-5390 Lower the platform onto the safety arm. Turn the machine off. GS-5390 Crushing hazard. Keep hands Bodily injury hazard. The clear of the safety arm when counterbalance valve in the lift lowering the platform.
Page 61 June 2021 Service and Repair Manual Scissor Components Attach a lifting strap from an overhead crane Remove the lift cylinder rod-end pivot pin or similar lifting device to the lifting eye at the retaining fastener. Use a soft metal drift to rod end of the lift cylinder for support.
Page 62: Engines
Service and Repair Manual June 2021 Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the Deutz D2011L03i models: engine and the pump. It is bolted to the engine Refer to Maintenance Procedure in the appropriate flywheel and has a splined center to drive the Service or Maintenance Manual for your machine, pump.
Page 63: How To Remove The Flex Plate - Deutz Models
June 2021 Service and Repair Manual Engines How to Remove the Flex Plate - How to Remove the Flex Plate - Deutz Models Remove the exhaust pipe, located between the exhaust manifold and muffler, from the Deutz Models machine. Release the latches on the engine tray and Remove the medium pressure filter assembly fully slide the engine tray out.
Page 64: How To Install The Flex Plate
Service and Repair Manual June 2021 Engines the appropriate gap between coupler and How to Install the Flex Plate How to Install the Flex Plate pump end plate for your engine. Install the flex plate onto the engine flywheel with the raised spline towards the pump. Ford models: Torque the flex plate mounting bolts in sequence to 14 ft-lbs / 19 Nm.
Page 65: Ford Msg-425 Engine Fault Codes
June 2021 Service and Repair Manual Engines Engine Fault Codes - Ford MSG-425 Models How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle position to maintain the engine's running condition...
Page 66: Engine Fault Codes - Deutz D 2.9 L4 And Perkins 404F-22 Models
Service and Repair Manual June 2021 Engines Engine Fault Codes - Deutz D 2.9 L4 Models How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine. The ECM also uses signals from the sensors to initiate sequential fuel injection and make constant and instantaneous changes to ignition timing, fuel delivery and throttle...
Page 67: Ground Controls
June 2021 Service and Repair Manual Ground Controls Controller Adjustments Auxiliary Platform Lowering All machine function speeds are determined by the In the event of an engine failure, activating the percentage of total ECM voltage output. The backup manual lowering and manual lowering speeds of the following machine functions may be enable switches will lower the platform when the adjusted to compensate for wear in the hydraulic...
Page 68: How To Determine The Revision Level
Service and Repair Manual June 2021 Ground Controls How to Determine the Revision How to Determine the Revision Level Use the yellow platform down arrow to scroll to max fwd high speed drive. Level Result: MAX FWD HIGH SPEED drive is Turn the key switch to ground control and pull showing in the diagnostic display window.
Page 69: How To Adjust The High Torque Drive Speed
June 2021 Service and Repair Manual Ground Controls How to Adjust the High Torque How to Adjust the High Torque Drive Speed 12 Press the lift function enable button. Drive Speed 13 Press the yellow platform down button to decrease the drive speed or press the blue Tip-over hazard.
Page 70: How To Adjust The Raised Drive Speed
Service and Repair Manual June 2021 Ground Controls How to Adjust the Raised Drive How to Adjust the Raised Drive Speed Press the yellow platform down button to decrease the drive speed or press the blue Speed platform up button to increase the drive speed.
Page 71 June 2021 Service and Repair Manual Ground Controls Press the lift function enable button. 13 Press the yellow platform down button to decrease the drive speed or press the blue Use the yellow platform down arrow to scroll platform up button to increase the drive to max fwd raised drive speed.
Page 72: How To Adjust The Lift Speed
Service and Repair Manual June 2021 Ground Controls How to Adjust the Lift Speed How to Adjust the Lift Speed Press the lift function enable button. 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 machine to tip over resulting in...
Page 73: How To Adjust The Platform Lower Speed
June 2021 Service and Repair Manual Ground Controls How to Adjust the Platform Lower How to Adjust the Platform Lower Speed Press the lift function enable button. Speed Press the yellow platform down button to decrease the platform descent speed or press Pull out the red Emergency stop button to the the blue platform up button to increase the on position at the platform controls.
Page 74: How To Adjust The Platform Settling Speed
Service and Repair Manual June 2021 Ground Controls How to Adjust the Platform How to Adjust the Platform Settling Speed Press the lift function enable button. Settling Speed Press the yellow platform down button to decrease the platform settling speed or press Pull out the red Emergency stop button to the the blue platform up button to increase the on position at the platform controls.
Page 75: How To Adjust The Steer Speed
June 2021 Service and Repair Manual Ground Controls How to Adjust the Steer Speed How to Adjust the Steer Speed Software Configuration Pull out the red Emergency stop button to the on position at the platform controls. The Electronic Control Module (ECM) contains Push in the ground controls red Emergency programming for all configurations of the GS- Stop button to the off position.
Page 76 Service and Repair Manual June 2021 Ground Controls Outriggers: When installed on the machine, the Press and hold both the blue platform up and outrigger option must be enabled. yellow platform down buttons. Pull out the red Emergency Stop button to the on position at Oscillating Axle: When installed on the machine, the ground controls.
Page 77 June 2021 Service and Repair Manual Ground Controls Press the lift function enable button to activate 14 Use the yellow platform down arrow to scroll the model/power option. to sim operation. Result: SELECT MODEL is showing in the Result: SIM OPERATION ON is showing in diagnostic display window.
Page 78 Service and Repair Manual June 2021 Ground Controls ANSI and CSA models with all software Use the yellow platform down arrow to scroll revisions: to select model. Result: SELECT MODEL is showing in the 18 Use the yellow platform down arrow to scroll diagnostic display window.
Page 79 June 2021 Service and Repair Manual Ground Controls 10 Use the yellow platform down arrow to scroll 15 Use the yellow platform down arrow to scroll to motion alarm. to beacons option. Result: MOTION ALARM is showing in the Result: BEACONS OFF is showing in the diagnostic display window.
Page 80: Level Sensor - Models Without Outriggers
Service and Repair Manual June 2021 Ground Controls Tag and disconnect the wire harness from the level sensor. Level Sensor - Models without Outriggers Remove the level sensor retaining fasteners and remove the level sensor from the machine. The Electronic Control Module (ECM) is programmed to deactivate the lift and drive Install the new level sensor onto the machine functions and activate an alarm when a signal is...
Page 81 June 2021 Service and Repair Manual Ground Controls 10 Tighten the level sensor adjusting fasteners 21 Raise the machine approximately 4 inches / until the bubble in the top of the level sensor 10 cm. is centered in the circles. 22 Models with RT tires: Place a 3 x 10 x Note: Be sure there are threads showing through 10 inch / 7.62 x 25 x 25 cm thick steel block...
Page 82: Level Sensor - Models With Outriggers
Service and Repair Manual June 2021 Ground Controls How to Install the Outrigger Level How to Install and Calibrate the Level Sensor - Models with Outriggers Level Sensor - Models with Sensor - Models with Outriggers Outriggers Tip-over hazard. Failure to install or calibrate the level sensor as The Electronic Control Module (ECM) is instructed will compromise...
Page 83 June 2021 Service and Repair Manual Ground Controls 10 Install the new level sensor onto the machine 15 Without disconnecting the wire harness from with the "X" on the level sensor base towards the level sensor, connect the positive lead of the steer end of the machine.
Page 84 Service and Repair Manual June 2021 Ground Controls Confirm the side-to-side level sensor setting: 37 Models with RT tires: Place a 3 x 10 x 10 inch / 7.62 x 25 x 25 cm thick steel block 26 Center a lifting jack under the drive chassis at under both wheels at the ground controls side the ground control side of the machine.
Page 85 June 2021 Service and Repair Manual Ground Controls 47 Lower the machine onto the blocks. 57 Raise the platform approximately 16 feet / 5 m. 48 Raise the platform approximately 16 feet / 5 m. Result: The platform stops raising and the tilt alarm will sound at 180 beeps per minute.
Page 86: Hydraulic Pump
Service and Repair Manual June 2021 Hydraulic Pump 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. Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose Tag, disconnect and plug the hydraulic hoses...
Page 87: Drive Pump
June 2021 Service and Repair Manual Hydraulic Pump Tag, disconnect and plug the hydraulic hoses from the drive pump. Cap the fittings on the Drive Pump pump. The drive pump is a bi-directional variable Bodily injury hazard. Spraying displacement piston pump. The pump output is hydraulic oil can penetrate and controlled by the electronic displacement controller burn skin.
Page 88: How To Prime The Pump
Service and Repair Manual June 2021 Hydraulic Pump How to Prime the Drive Pump How to Prime the Pump Crank the engine with the starter motor for 15 seconds, wait 15 seconds, then crank the Component damage hazard. engine an additional 15 seconds or until the The engine must not be started pressure reaches 325 psi / 22.4 bar.
Page 89: How To Adjust The Pump Neutral
June 2021 Service and Repair Manual Hydraulic Pump How to Adjust the Pump Neutral How to Adjust the Pump Neutral 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. Raise the drive wheels off the ground and set 10 While holding the adjustment screw in the chassis on blocks.
Page 90 Service and Repair Manual June 2021 This page intentionally left blank. GS-84 • GS-90 Part No. 1272222GT...
Page 91: Manifolds
June 2021 Service and Repair Manual 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 Function Torque Item Check valve, 5 psi / 0.3 bar Platform down circuit 40 - 45 ft-lbs 54 - 61 Nm...
Page 92 Service and Repair Manual June 2021 Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. GS-84 • GS-90 Part No. 1272222GT...
Page 93: Function Manifold Components - Models Without Outriggers
June 2021 Service and Repair Manual 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 Function Torque Item Check valve, 5 psi / 0.3 bar Platform down circuit 40 - 45 ft-lbs 54 - 61 Nm...
Page 94 Service and Repair Manual June 2021 Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. GS-84 • GS-90 Part No. 1272222GT...
Page 95: Traction Manifold Components
June 2021 Service and Repair Manual Manifolds Traction Manifold Components The traction manifold is located under the function manifold Index Schematic Description Function Torque Item Flow divider/combiner valve Controls flow to front and rear 95 - 100 ft-lbs drive motors 129 - 135 Nm Orifice Plug, 0.043 inch / 1.1 mm Balances flow from flow...
Page 96 Service and Repair Manual June 2021 Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. GS-84 • GS-90 Part No. 1272222GT...
Page 97: Oscillate Manifold Components, Gs-90 (Option)
June 2021 Service and Repair Manual Manifolds Oscillate Manifold Components, GS-90 (option) The oscillate manifold is located under the function manifold. Index Schematic Description Function Torque Item Solenoid valve, 2 position 2 way Oscillate circuit 45 ft-lbs / 61 Nm Relief valve, 3500 psi / 241.3 bar System relief 25 - 30 ft-lbs...
Page 98 Service and Repair Manual June 2021 Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. GS-84 • GS-90 Part No. 1272222GT...
Page 99: Welder Manifold Components (Option)
June 2021 Service and Repair Manual Manifolds Diverter Manifold Components (welder option) The welder manifold is located under the drive manifold. Index Schematic Description Function Torque Item Directional valve Diverter valve 80-90 ft-lbs / 108-122 Nm Orifice, 0.030 inch / .76 mm Delays shift to drive 35-40 ft-lbs / 47-54 Nm Solenoid Valve, 2 position 3 way...
Page 100: Valve Adjustments - Function Manifold
Service and Repair Manual June 2021 Manifolds 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 Valve How to Adjust the System Relief 1135 kg Valve...
Page 101: How To Adjust The Steer Relief Valve
June 2021 Service and Repair Manual Manifolds How to Adjust the Steer Relief How to Adjust the Steer Relief Valve 11 Adjust the internal hex socket. Turn it clockwise to increase the pressure or Valve counterclockwise to decrease the pressure. Install the relief valve cap.
Page 102: Valve Adjustments - Traction Manifold
Service and Repair Manual June 2021 Manifolds Valve Adjustments - Traction Manifold How to Adjust the Charge Pressure Relief Valve How to Adjust the Charge Pressure Relief Valve Note: Refer to Drive Manifold Component list to locate the charge pressure relief valve. Connect a 0 to 600 psi / 0 to 50 bar pressure gauge to test port #2 on the drive manifold.
Page 103: Generator Manifold Components
June 2021 Service and Repair Manual Repair Procedures Generator Manifold Components The generator manifold is located below the ground controls. Index Schematic Description Function Torque Item Solenoid operated 2 position, 3 way Generator on/off 25 ft-lbs / 34 Nm directional valve Flow regulator valve, 4.3 gpm / 16.3 L/min Generator speed 20 ft-lbs / 27 Nm...
Page 104: Valve Adjustments - Generator Manifold
Service and Repair Manual June 2021 Manifolds Connect the positive and negative leads from a multimeter of sufficient capacity to the Valve Adjustments - Generator electrical outlet at the generator. Manifold Result: The reading on the multimeter should be 112 to 118V AC. How to Adjust the Generator Voltage Result: If the reading on the multimeter is not How to Adjust the Generator...
Page 105: Generator Relief Valve Manifold Components
June 2021 Service and Repair Manual Repair Procedures 7-10 Generator Relief Valve Manifold Components The generator relief valve manifold is located in the hydraulic manifold compartment. Index Schematic Description Function Torque Item Relief valve, 3500 psi / 241 bar Generator pressure circuit 25 ft-lbs / 34 Nm Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic.
Page 106: Valve Coils
Service and Repair Manual June 2021 Manifolds 7-11 Valve Coils Valve Coil Resistance Specification How to Test a Coil Note: The following coil resistance specifications are at an ambient temperature of 68°F / 20°C. As A properly functioning coil provides an valve coil resistance is sensitive to changes in air electromotive force which operates the solenoid temperature, the coil resistance will typically...
Page 107 June 2021 Service and Repair Manual Manifolds How to Test a Coil Diode Properly functioning coil diodes 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. Faulty diodes can fail to protect the electrical system, resulting in a tripped circuit breaker or component damage.
Page 108: Fuel And Hydraulic Tanks
Service and Repair Manual June 2021 Fuel and Hydraulic Tanks Lower the platform onto the safety arm. Turn the machine off. Fuel Tank Crushing hazard. Keep hands clear of the safety arm when How to Remove the Fuel Tank lowering the platform. Explosion and fire hazard.
Page 109: Hydraulic Tank
June 2021 Service and Repair Manual Fuel and Hydraulic Tanks 11 Using an approved hand-operated pump, drain the fuel tank into a suitable container. Hydraulic Tank Refer to Specifications, Machine Specifications. The primary functions of the hydraulic tank are to cool, clean and deaerate the hydraulic fluid during Explosion and fire hazard.
Page 110 Service and Repair Manual June 2021 Fuel and Hydraulic Tanks Remove the drain plug from the hydraulic tank Lower the platform onto the safety arm. Turn and completely drain the tank into a suitable the machine off. container. Refer to Specifications, Machine Crushing hazard.
Page 111: Steer Axle Components
June 2021 Service and Repair Manual Steer Axle Components Tag, disconnect and plug the hoses from the drive motor. Cap the fittings on the drive Yoke and Drive Motor motor. How to Remove the Yoke and Drive Motor How to Remove the Yoke and Bodily injury hazard.
Page 112: How To Remove A Drive Motor
Service and Repair Manual June 2021 Steer Axle Components How to Remove a Drive Motor How to Remove a Drive Motor Remove the retaining fasteners from the drive motor guard. Remove the drive motor guard Component damage hazard. from the yoke. Repairs to the motor should only Tag, disconnect and plug the hoses from the be performed by an authorized...
Page 113: Steer Cylinder
June 2021 Service and Repair Manual Steer Axle Components Steer Cylinder Oscillating Axle Option - GS-90 Models How to Remove the Steer Cylinder How the Oscillating Axle Functions Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose When driving the GS-90 with the platform in the end must be replaced.
Page 114 Service and Repair Manual June 2021 Steer Axle Components When the left rear or right rear wheel 'drops', the Oscillate Raised Relay CR85 limit switch will relax and close its circuit, sending Terminal 30 of the Oscillate Raised relay, CR85, power to the appropriate oscillating valve coil.
Page 115: Non-Steer Axle Components
June 2021 Service and Repair Manual Non-steer Axle Components Note: There are two O-rings on the drive motor 10-1 and brake assembly. One is installed between the Drive Motor and Brake brake and drive hub and another between the brake and drive motor. Be sure that both O-rings How to Remove a Drive Motor and Brake are in place when installing the brake and drive motor onto the machine.
Page 116: Drive Hub
Service and Repair Manual June 2021 Non-steer Axle Components 10-2 Remove the drive hub mounting bolts that attach the drive hub to the axle. Remove the Drive Hub drive hub. How to Remove a Drive Hub Crushing hazard. The drive hub may become unbalanced and fall How to Remove a Drive Hub if it is not properly supported and...
Page 117: Oscillating Axle
June 2021 Service and Repair Manual Non-steer Axle Components 10-3 Oscillating Axle Refer to Repair Procedure, Oscillating Axle Option - GS-90 Models Part No. 1272222GT GS-84 • GS-90...
Page 118: Outrigger Components
Service and Repair Manual June 2021 Outrigger Components Remove the outrigger cylinder mounting 11-1 fasteners. Remove the outrigger cylinder from the machine. Outrigger Cylinder Crushing hazard. The outrigger How to Remove an Outrigger Cylinder (if equipped) cylinder may become unbalanced and fall if not How to Remove an Outrigger properly supported when it is Cylinder (if equipped)
Page 119: Platform Overload Components
June 2021 Service and Repair Manual Platform Overload Components 12-1 Using a suitable lifting device, place a test weight, corresponding to the maximum load Platform Overload System (if as indicated on the capacity indicator decal, in equipped) the center of the platform floor. Secure the weight to the platform.
Page 120 Service and Repair Manual June 2021 Platform Overload Components GS-3384, GS-3390 and GS-4390 models: Set the pressure switch 14 Pull out the red Emergency Stop button to the 16 Turn the nut (or adjustment screw) of the on position at the ground controls. Wait platform overload pressure switch out of the 3 seconds and start the engine.
Page 121 June 2021 Service and Repair Manual Platform Overload Components Set the maximum height limit switch 26 Raise the platform in 2 inch / 5 cm increments until the overload alarm sounds and the 21 Using a suitable lifting device, place a test engine stops running.
Page 122 Service and Repair Manual June 2021 Platform Overload Components 29 Start the engine and fully raise the platform. 33 Raise the platform until the position indicator corresponds to the maximum load position of Result: The engine continues to run. Proceed the capacity indicator decal.
Page 123 June 2021 Service and Repair Manual Platform Overload Components Set the maximum height pressure switch 35 Slowly turn the adjustment screw of the platform overload pressure switch into the 34 Working on platform overload pressure switch hydraulic line in 90° increments just until the 1 (parallel to the cylinder on early models) overload alarm doesn't sound and the engine with a small slotted screwdriver, turn the...
Page 124 Service and Repair Manual June 2021 Platform Overload Components Set the maximum height limit switch 41 Slowly turn the adjustment screw of the platform overload pressure switch into the 46 Using a suitable lifting device, place a test hydraulic line in 90° increments just until the weight in the center of the platform floor.
Page 125 June 2021 Service and Repair Manual Platform Overload Components All models: 52 Install and adjust the maximum height limit switch cam until the limit switch activates just Disable the descent delay function before the point reached in step 51. Securely 59 Push in the ground controls red Emergency tighten the cam fasteners.
Page 126 Service and Repair Manual June 2021 Platform Overload Components Enable the descent delay function 65 Push in the ground controls red Emergency Stop button to the off position. 76 Push in the ground controls red Emergency 66 Pull out the red Emergency Stop button to the Stop button to the off position.
Page 127 June 2021 Service and Repair Manual Platform Overload Components Calibrate the down limit switch 94 Lower the platform to the stowed position. Remove the weight from the platform. 84 Turn the key switch to platform controls. Start Result: The platform lowers to the stowed the engine.
Page 128: Platform Overload Recovery Message (Software Version B3 And Later)
Service and Repair Manual June 2021 Platform Overload Components 12-2 Use the down button to scroll to select options. Platform Overload Recovery Message (software version Press the lift function enable button. B3 and later) Result: Descent delay is showing in the LCD screen.
Page 129 June 2021 Service and Repair Manual This page intentionally left blank. Part No. 1272222GT GS-84 • GS-90...
Page 130: Fault Codes
Service and Repair Manual June 2021 Fault Codes Section 4 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 ...
Page 131 June 2021 Service and Repair Manual Fault Codes About This Section 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 —...
Page 132: Control System Fault Codes
Service and Repair Manual June 2021 Fault Codes System Ready LED Condition Result Solution INTERNAL ECU Internal ECM error. System shutdown. Replace ECM. FAULT PLATFORM ECU Platform/ECM System shutdown. Troubleshoot control cable OR FAULT communication error. troubleshoot platform controls. CHASSIS START Engine start button fault at Engine will not Replace ECM.
Page 133 June 2021 Service and Repair Manual Fault Codes System Ready LED Condition Result Solution PLATFORM Engine start button fault at Engine will not start. Troubleshoot button OR START SW platform controls. replace printed circuit board FAULT at platform controls. LEFT FRONT Left front outrigger enable Outriggers disabled.
Page 134 Service and Repair Manual June 2021 Fault Codes System Ready LED Condition Result Solution DRIVE COIL 2 Drive coil 2 (Y1A) fault. High speed drive Troubleshoot coil OR wiring. FAULT function will not operate. DRIVE COIL 3 Drive coil 3 (Y1B) fault. High speed drive Troubleshoot coil OR wiring.
Page 135 June 2021 Service and Repair Manual Fault Codes System Ready LED Condition Result Solution HIGH COOLANT High coolant temperature. High engine Gasoline/LPG models: Check TEMPERATURE temperature OR the engine radiator coolant defective engine level OR check the wiring from coolant or oil the water temperature switch temperature switch.
Page 136: Fault Code Display - Deutz Models
Service and Repair Manual June 2021 Fault Code Display - Deutz Models How to Retrieve Active Engine How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 Models With an active fault and the engine running: (preferred method) Fault Codes - Deutz D 2.9 L4 Models At the ground controls, activate the auxiliary pump toggle switch to shut the engine off.
Page 137: Fault Code Display - Flashing And Solid Led's - Deutz D 2.9 L4 Models
June 2021 Service and Repair Manual Fault Code Display - Deutz Models Flashing and Solid LED's - Deutz D 2.9 L4 Models Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 Models 1 Left green LED: Flashing, engine fault detected.
Page 138: Soft Key Functions And Icons - Deutz D 2.9 L4 Models
Service and Repair Manual June 2021 Fault Code Display - Deutz Models Soft Key Functions and Icons - Deutz D 2.9 L4 Models Soft Key Functions and Icons - Deutz D 2.9 L4 Models Next menu • Exit / Back one screen • Decrease brightness (-) Brightness / Contrast •...
Page 139: Main Menu Structure - Deutz D 2.9 L4 Models
June 2021 Service and Repair Manual Fault Code Display - Deutz Models Main Menu Structure - Deutz D 2.9 L4 Models Main Menu Structure - Deutz D 2.9 L4 Models Part No. 1272222GT GS-84 • GS-90...
Page 140: Deutz D 2.9 L4 Engine Fault Codes
Service and Repair Manual June 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1231 Actuator error EGR-Valve; KWP = Keyword Protocol Power stage over temp due to high current SPN FMI Description...
Page 141 June 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1180 Physical range check high for KWP = Keyword Protocol battery voltage SPN FMI Description 1181 Physical range check low for...
Page 142 Service and Repair Manual June 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1007 Sensor error EGR cooler KWP = Keyword Protocol downstream temperature; signal range check high SPN FMI Description 1008...
Page 143 June 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 1109 2 Engine shut off demand ignored KWP = Keyword Protocol 1136 0 1398 Physikal range check high for SPN FMI Description...
Page 144 Service and Repair Manual June 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number SPN FMI Description FMI = Failure Mode Identifier 2659 2 1527 AGS sensor temperature KWP = Keyword Protocol exhaust gas mass flow; plausibility error SPN FMI Description...
Page 145 June 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523212 Timeout Error of CAN-Receive- KWP = Keyword Protocol Frame ComEngPrt; Engine Protection FMI KWP Description 523216 Timeout Error of CAN-Receive-...
Page 146 Service and Repair Manual June 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523612 Internal ECU monitoring KWP = Keyword Protocol detection reported error FMI KWP Description 523612 1170 Internal software error ECU 523605...
Page 147 June 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI SPN Description FMI = Failure Mode Identifier 523788 Timeout Error of CAN-Transmit- KWP = Keyword Protocol Frame TrbCH; Status Wastegate FMI KWP Description 523793 Timeout Error of CAN-Receive- Frame UAA10;...
Page 148 Service and Repair Manual June 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 523946 1164 Zero fuel calibration injector 1 (in KWP = Keyword Protocol firing order); minimum value exceeded FMI KWP Description 523947...
Page 149 June 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number FMI KWP Description FMI = Failure Mode Identifier 524032 1442 EGR actuator; status message KWP = Keyword Protocol EGRCust is missing FMI KWP Description 524033 1443 EGR actuator;...
Page 150 Service and Repair Manual June 2021 Deutz D 2.9 L4 Engine Fault Codes SPN = Suspect Parameter Number KWP Description FMI = Failure Mode Identifier 524114 9 1659 Timeout error of CAN-Transmit- KWP = Keyword Protocol Frame A1DOC KWP Description 524115 9 1660 Timeout error of CAN-Transmit- Frame AT1S...
Page 151: Ford Msg-425 Engine Fault Codes
June 2021 Service and Repair Manual Ford MSG-425 Engine Fault Codes Note: Once a fault code has been retrieved and How to Retrieve Ford Engine How to Retrieve Ford Engine Fault Codes the repair has been completed, the ECM memory Fault Codes must be reset to clear the fault code from the ECM.
Page 152: Ford Msg-425 Engine Fault Codes
Service and Repair Manual June 2021 Ford MSG-425 Engine Fault Codes Code Description Code Description Never crank synced at start TIP Low Voltage FP low voltage TIP High Voltage FP high voltage Injector Loop Open or Low-side short to Ground MAP Low Voltage Injector Coil Shorted MAP High Pressure...
Page 153 June 2021 Service and Repair Manual Ford MSG-425 Engine Fault Codes Code Description Code Description Emissions/catalyst damaging misfire 5VE1 low voltage Emissions/catalyst damaging misfire 5VE1 high voltage Emissions/catalyst damaging misfire MIL open Emissions/catalyst damaging misfire 5VE2 low voltage Emissions/catalyst damaging misfire 5VE2 high voltage Emissions/catalyst damaging misfire Relay Coil Open...
Page 154 Service and Repair Manual June 2021 Ford MSG-425 Engine Fault Codes Code Description Code Description 1173 Megajector comm lost 1551 AUX DIG1 high 1174 Megajector voltage supply high 1552 AUX DIG1 low 1175 Megajector voltage supply low 1553 AUX DIG2 high 1176 Megajector internal actuator fault detection 1554...
Page 155 June 2021 Service and Repair Manual Ford MSG-425 Engine Fault Codes Code Description Code Description 1629 J1939 TSC1 message receipt lost 2130 IVS stuck at-idle, FPP1/2 match 1630 J1939 ETC message receipt lost 2131 IVS stuck off-idle, FPP1/2 match 1631 PWM1-Gauge1 open / ground short 2135 TPS1/2 simultaneous voltages out of range...
Page 156 Service and Repair Manual June 2021 Ford MSG-425 Engine Fault Codes Code Description 2309 Primary Loop Open or Low-side Short to Ground 2310 Primary Coil Shorted 2312 Primary Loop Open or Low-side Short to Ground 2313 Primary Coil Shorted Primary Loop Open or Low-side Short to 2315 Ground 2316...
Page 157: Schematics
June 2021 Service and Repair Manual Schematics About This Section Section 5 Schematics There are two groups of schematics in this section. Electrical Schematics Electrocution/burn hazard. Contact with electrically charged Observe and Obey: circuits could result in death or serious injury. Remove all rings, Troubleshooting and repair procedures shall ...
Page 158: Electrical Symbols Legend
Service and Repair Manual June 2021 Electrical Symbols Legend Battery Motor Horn or alarm Flashing beacon Gauge Circuit breaker with Diode Coil with suppression Fuse with amperage amperage Level sensor Connection - no Circuits crossing no Quick disconnect Power relay terminal connection terminal...
Page 159: Hydraulic Symbols Legend
June 2021 Service and Repair Manual Hydraulic Symbols Legend Orifice with size Check valve Cylinder, double acting Accumulator Pump, prime mover Pump, fixed displacement Pressure switch Needle valve (engine or motor) Solenoid operated Solenoid operated Solenoid operated Solenoid operated 3 position 4 way directional 3 position 5 way 2 position, 3 way directional 2 position 2 way directional...
Page 160: Electrical Component And Wire Color Legends
Service and Repair Manual June 2021 Electrical Component and Wire Color Legends Item Description Joystick Controller Battery Key switch Button Motor Engine start (PCON) Auxiliary pump Starting aid (PCON) Engine starter High idle (PCON) Fuel pump Horn (PCON) N.C. Normally Closed High torque (PCON) N.O.
Page 161 June 2021 Service and Repair Manual Electrical Component and Wire Color Legends Item Wire Color Legend Description Valve Coil Item Description Brake release Blue Steer right Black Steer left Brown Platform down Grey Platform up Orange Proportional control Purple Two speed Generator on (option) White Left rear outrigger...
Page 162: Ford Engine Relay Layout
Service and Repair Manual June 2021 Ford Engine Relay Layout Ford MSG-425 EFI Power Relay Fuel Pump Relay Empty Starter - 20A Fuse 1 - 10A, Battery voltage to EPR Fuse 2 - 5A, Ignition voltage to GCP and relays Fuse 3 - 10A, Battery voltage to GCP Fuse 4 - 15A, Fuel pump Fuse 5 - 15A, Battery voltage out of Power Relay...
Page 163: Electronic Control Module Layout
June 2021 Service and Repair Manual Electronic Control Module Layout 9 electronic control module 1 pump 10 level sensor 2 engine 11 horn 3 to outriggers 12 ground controls 4 to platform overload 13 function manifold 5 down limit switch 14 drive manifold 6 up limit switch 15 oscillate manifold...
Page 164: Electronic Control Module Pin-Out Legend
Service and Repair Manual June 2021 Electronic Control Module Pin-Out Legend Plug Platform overload (input) Right front outrigger limit switch LS13 (input) Right rear outrigger limit switch LS15 (input) Left front outrigger limit switch LS12 (input) Left rear outrigger limit switch LS14 (input) J1 Connector Alternator (input) Description...
Page 165 June 2021 Service and Repair Manual Electronic Control Module Pin-Out Legend Ground (output) Plug Plug Auxiliary down relay CR23 terminal 87 (output) Flashing beacons FS1 (output) ECM power (input) J2 Connector Description Up limit switch LS5 (input) Down limit switch LS6 (input) Aux down power (input) Aux down relay CR23 terminal 86 (output) Key switch terminal 3 (input)
Page 166: Ground Controls Wiring Panel Layout
Service and Repair Manual June 2021 Ground Controls Wiring Panel Layout K1 1st E-Stop K7 Load sense (AS/CE models) K13 2nd load sense (AS/CE models) K2 2nd E-Stop K8 Oil cooler (option) K14 3rd load sense (AS/CE models) K3 Starter K9 1st up enable (GS-5390 models) K15 Descent overload K4 Ignition...
Page 167: Wiring Diagram - Platform Control Box
June 2021 Service and Repair Manual Wiring Diagram - Platform Control Box Part No. 1272222GT GS-84 • GS-90...
Page 168: Limit Switch Legend
Service and Repair Manual June 2021 Limit Switch Legend up limit switch LS5 (GS- 5390 models) (hydraulic tank side) up limit switch LS5A (GS- 5390 models) (hydraulic tank side) down limit switch LS6 (ground controls side) load sense delay LS25 (CE models) (ground controls side) maximum height LS24 (CE models) (ground controls side)
Page 169: Wiring Diagram - 12 Kw Hydraulic Generator (Option)
June 2021 Service and Repair Manual Wiring Diagram - 12 kW Hydraulic Generator (option) Part No. 1272222GT GS-84 • GS-90...
Page 170 Service and Repair Manual June 2021 Wiring Diagram - 12 kW Hydraulic Generator (option) Theory of Operation Turning on the Generator sends a signal to When the AC generator is turned OFF, the SX the ECU which deactivates the function as module will ramp the output to the EDC to long as the generator function is turned on.
Page 171: Electrical Schematics - Engine Harness
June 2021 Service and Repair Manual Ford MSG-425 Engine Wire Harness...
Page 172: Ford Msg-425 Efi Engine Wire Harness
Service and Repair Manual June 2021 Ford MSG-425 EFI Engine Wire Harness GS-84 • GS-90 Part No. 1272222GT...
Page 173: Deutx D 2.9 L4 Engine Wire Harness
June 2021 Service and Repair Manual Deutz D 2.9 L4 Engine Wire Harness Part No. 1272222GT GS-84 • GS-90...
Page 174 Service and Repair Manual June 2021 Deutz D 2.9 L4 Engine Wire Harness...
Page 175: Hydraulic Schematics
June 2021 Service and Repair Manual Hydraulic Schematic, To Serial Numbers GS8415-42316 and GS9015-50184...
Page 176: Hydraulic Schematic, To Serial Numbers Gs8415-42316 And Gs9015-50184
Service and Repair Manual June 2021 Hydraulic Schematic, To Serial Numbers GS8415-42316 and GS9015-50184 GS-84 • GS-90 Part No. 1272222GT...
Page 177 June 2021 Service and Repair Manual Hydraulic Schematic, From Serial Numbers GS8415-42317 and GS9015-50185...
Page 178: From Serial Numbers Gs84154-42317 And Gs9015-50185
Service and Repair Manual June 2021 Hydraulic Schematic, From Serial Numbers GS8415-42317 and GS9015-50185 GS-84 • GS-90 Part No. 1272222GT...
Page 179 June 2021 Service and Repair Manual Hydraulic Schematic, From Serial Numbers GS8415-42317 and GS9015-50185 Part No. 1272222GT GS-84 • GS-90...
Page 180 Service and Repair Manual June 2021 Hydraulic Schematic, From Serial Numbers GS8415-42317 and GS9015-50185...
Page 181: Electrical Schematics - Ansi And Csa Models
June 2021 Service and Repair Manual Electrical Schematic, Ford Engine Models (ANSI/CSA) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948)
Page 182: Electrical Schematic, Ford Engine Models (Ansi/Csa) (From Gs84D-101) • (To Gs84F-45671, Gs90D-2776, Gs90F-54948)
Service and Repair Manual June 2021 Electrical Schematic, Ford Engine Models (ANSI/CSA) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948) GS-84 • GS-90 Part No. 1272222GT...
Page 183: Electrical Schematic, Ford Engine Models (Ansi/Csa) (From Gs84F-45672 To 45680, Gs90D-2777 To 2861, Gs90F-54949 To 55081)
June 2021 Service and Repair Manual Electrical Schematic, Ford Engine Models (ANSI/CSA) (from GS84F-45672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081) Part No. 1272222GT GS-84 • GS-90...
Page 184 Service and Repair Manual June 2021 Electrical Schematic, Ford Engine Models (ANSI/CSA) (from GS84F-45672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081)
Page 185 June 2021 Service and Repair Manual Electrical Schematic, Ford Engine Models (ANSI/CSA) (from GS84F-45681, GS90D-2862, GS90F-55082)
Page 186: Electrical Schematic, Ford Engine Models (Ansi/Csa) (From Gs84F-45681, Gs90D-2862, Gs90F-55082)
Service and Repair Manual June 2021 Electrical Schematic, Ford Engine Models (ANSI/CSA) (from GS84F-45681, GS90D-2862, GS90F-55082) GS-84 • GS-90 Part No. 1272222GT...
Page 187: Platform Controls, Ford Engine Models (Ansi/Csa)
June 2021 Service and Repair Manual Platform Controls, Ford Engine Models (ANSI/CSA) Part No. 1272222GT GS-84 • GS-90...
Page 188 Service and Repair Manual June 2021 Platform Controls, Ford Engine Models (ANSI/CSA)
Page 189 June 2021 Service and Repair Manual Electrical Schematic, Deutz Engine Models (ANSI/CSA) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948)
Page 190: Electrical Schematic, Deutz Engine Models (Ansi/Csa) (From Gs84D-101) • (To Gs84F-45671, Gs90D-2776, Gs90F-54948)
Service and Repair Manual June 2021 Electrical Schematic, Deutz Engine Models (ANSI/CSA) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948) GS-84 • GS-90 Part No. 1272222GT...
Page 191: Electrical Schematic, Deutz Engine Models (Ansi/Csa) (From Gs84F-45672 To 45680, Gs90D-2777 To 2861, Gs90F-54949 To 55081)
June 2021 Service and Repair Manual Electrical Schematic, Deutz Engine Models (ANSI/CSA) (from GS84F-45672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081) Part No. 1272222GT GS-84 • GS-90...
Page 192 Service and Repair Manual June 2021 Electrical Schematic, Deutz Engine Models (ANSI/CSA) (from GS84F-45672 to 45680, GS90D-2777 to 2862, GS90F-54949 to 55081)
Page 193 June 2021 Service and Repair Manual Electrical Schematic, Deutz Engine Models (ANSI/CSA) (from GS84F-45681, GS90D-2862, GS90F-55082)
Page 194: Electrical Schematic, Deutz Engine Models (Ansi/Csa) (From Gs84F-45681, Gs90D-2862, Gs90F-55082)
Service and Repair Manual June 2021 Electrical Schematic, Deutz Engine Models (ANSI/CSA) (from GS84F-45681, GS90D-2862, GS90F-55082) GS-84 • GS-90 Part No. 1272222GT...
Page 195: Platform Controls, Deutz Engine Models (Ansi/Csa)
June 2021 Service and Repair Manual Platform Controls, Deutz Engine Models (ANSI/CSA) Part No. 1272222GT GS-84 • GS-90...
Page 196 Service and Repair Manual June 2021 Platform Controls, Deutz Engine Models (ANSI/CSA)
Page 197: Electrical Schematics - As And Ce Models
June 2021 Service and Repair Manual Electrical Schematic, Ford Engine Models (AS/CE) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948)
Page 198: Electrical Schematic, Ford Engine Models (As/Ce) (From Gs84D-101) • (To Gs84F-45671, Gs90D-2776, Gs90F-54948)
Service and Repair Manual June 2021 Electrical Schematic, Ford Engine Models (AS/CE) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948) GS-84 • GS-90 Part No. 1272222GT...
Page 199: Electrical Schematic, Ford Engine Models (As/Ce) (From Gs84F-54672 To 45680, Gs90D-2777 To 2861, Gs90F-54949 To 55081)
June 2021 Service and Repair Manual Electrical Schematic, Ford Engine Models (AS/CE) (from GS84F-54672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081) Part No. 1272222GT GS-84 • GS-90...
Page 200 Service and Repair Manual June 2021 Electrical Schematic, Ford Engine Models (AS/CE) (from GS84F-45672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081)
Page 201 June 2021 Service and Repair Manual Electrical Schematic, Ford Engine Models (AS/CE) (from GS84F-45681, GS90D-2862, GS90F-55082)
Page 202: Electrical Schematic, Ford Engine Models (As/Ce) From Gs84F-45681, Gs90D-2862, Gs90F-55082)
Service and Repair Manual June 2021 Electrical Schematic, Ford Engine Models (AS/CE) (from GS84F-45681, GS90D-2862, GS90F-55082) GS-84 • GS-90 Part No. 1272222GT...
Page 203: Platform Controls, Ford Engine Models (As/Ce)
June 2021 Service and Repair Manual Platform Controls, Ford Engine Models (AS/CE) Part No. 1272222GT GS-84 • GS-90...
Page 204 Service and Repair Manual June 2021 Platform Controls, Ford Engine Models (AS/CE)
Page 205 June 2021 Service and Repair Manual Electrical Schematic, Deutz Engine Models (AS/CE) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948)
Page 206: Electrical Schematic, Deutz Engine Models (As/Ce) (From Gs84D-101) • (To Gs84F-45671, Gs90D-2776, Gs90F-54948)
Service and Repair Manual June 2021 Electrical Schematic, Deutz Engine Models (AS/CE) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948) GS-84 • GS-90 Part No. 1272222GT...
Page 207: Electrical Schematic, Deutz Engine Models (As/Ce) (From Gs84F-45672 To 45680, Gs90D-2777 To 2861, Gs90F-54949 To 55081)
June 2021 Service and Repair Manual Electrical Schematic, Deutz Engine Models (AS/CE) (from GS84F-45672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081) Part No. 1272222GT GS-84 • GS-90...
Page 208 Service and Repair Manual June 2021 Electrical Schematic, Deutz Engine Models (AS/CE) (from GS84F-45672 to 45680, GS90D-2777 to 2862, GS90F-54949 to 55081)
Page 209 June 2021 Service and Repair Manual Electrical Schematic, Deutz Engine Models (AS/CE) (from GS84F-45681, GS90D-2862, GS90F-55082)
Page 210: Electrical Schematic, Deutz Engine Models (As/Ce) (From Gs84F-45681, Gs90D-2862, Gs90F-55082)
Service and Repair Manual June 2021 Electrical Schematic, Deutz Engine Models (AS/CE) (from GS84F-45681, GS90D-2862, GS90F-55082) GS-84 • GS-90 Part No. 1272222GT...
Page 211: Platform Controls, Deutz Engine Models (As/Ce)
June 2021 Service and Repair Manual Platform Controls, Deutz Engine Models (AS/CE) Part No. 1272222GT GS-84 • GS-90...
Page 212 Service and Repair Manual June 2021 Platform Controls, Deutz Engine Models (AS/CE) GS-84 • GS-90 Part No. 1272222GT Service and Repair Manual June 2021...

Terex Genie GS-3390 Service And Repair Manual

Introduction

Safety Rules

Specifications

Repair Procedures

Platform Controls

Platform Components

Scissor Components

Engines

Ground Controls

Hydraulic Pump

Manifolds

Fuel and Hydraulic Tanks

Steer Axle Components

Non-Steer Axle Components

Outrigger Components

Platform Overload Components

Fault Codes

Control System Fault Codes

Fault Code Display - Deutz Models

Deutz D 2.9 L4 Engine Fault Codes

Ford MSG-425 Engine Fault Codes

Schematics

Electrical Schematics - Engine Harness

Hydraulic Schematics

Electrical Schematics - ANSI and CSA Models

Electrical Schematics - as and CE Models

Quick Links

Need help?

Questions and answers

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Summary of Contents for Terex Genie GS-3390

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Table of Contents