Terex GS90D-4695 Service And Repair Manual
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Terex GS90D-4695 Service And Repair Manual

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Service and Repair Manual
GS
-3390
™
GS
-4390
™
GS
-5390
™
Serial Number Range
from GS90D-4695
from GS90M-101
This manual includes:
Repair procedures
Fault Codes
Electrical and
Hydraulic Schematics
For detailed maintenance
procedures, refer to the
appropriate Maintenance
Manual for your machine.
Original Instructions
Part No. 1325652GT
Rev A1
December 2023

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Summary of Contents for Terex GS90D-4695

  • Page 1 Service and Repair Manual Serial Number Range -3390 ™ from GS90D-4695 This manual includes: from GS90M-101 Repair procedures -4390 ™ Fault Codes Electrical and -5390 ™ Hydraulic Schematics For detailed maintenance procedures, refer to the appropriate Maintenance Manual for your machine.

  • Page 2: Introduction

    Copyright © 2016 by Terex Corporation 1325652GT Rev A, August 2023 Third Edition, First Printing Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. “GS” is a trademark of Terex South Dakota, Inc.

  • Page 3: Revision History

    December 2023 Service and Repair Manual Introduction Revision History Revision Date Section Procedure / Page / Description 8/2023 Initial Release Add facility code and serial break 12/2023 Front cover Reference Examples: Electronic Version Section – Repair Procedure, 4-2 Click on any content or procedure in the Table of Contents to view Section –...

  • Page 4: Serial Number Legend

    Service and Repair Manual December 2023 Introduction Serial Number Legend 1 Model 2 Facility code 3 Sequence number 4 Serial number, (stamped on chassis) 5 Serial label, (located inside cover) -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™...

  • Page 5: Safety Rules

    December 2023 Service and Repair Manual Safety Rules Section 1 Safety R ules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator's Manual on your machine will result in death or serious injury. Many of the hazards identified in the operator's manual are also safety hazards when maintenance and repair procedures are...
  • Page 6 Service and Repair Manual December 2023 Safety Rules Personal Safety Workplace Safety Any person working on or around a machine must Any person working on or around a machine must be aware of all known safety hazards. Personal be aware of all known safety hazards. Personal safety and the continued safe operation of the safety and the continued safe operation of the machine should be your top priority.

  • Page 7: Table Of Contents

    December 2023 Table of Contents Introduction Introduction ......................ii Important Information ..................... ii Find a Manual for this Model .................. ii Revision History..................... iii Serial Number Legend ..................iv Section 1 Safety Rules ......................v General Safety Rules ..................... v Section 2 Specifications .......................
  • Page 8 December 2023 Table of Contents Section 3 Repair Procedures ....................18 Introduction ......................18 Platform Controls ....................20 1-1 Circuit Board ....................20 How to Remove the Platform Controls Circuit Board ........20 Platform Components ..................21 2-1 Platform ......................21 How to Remove the Platform ................
  • Page 9 December 2023 Table of Contents Engines ........................ 52 4-1 RPM Adjustment .................... 52 4-2 Flex Plate ....................... 52 How to Remove the Flex Plate - Ford Models ..........52 How to Remove the Flex Plate - Deutz, Weichai Models ....... 53 How to Install the Flex Plate ................
  • Page 10 December 2023 Table of Contents Hydraulic Pump ....................77 6-1 Lift/Steer Pump ....................77 How to Remove the Lift/Steer Pump ............... 77 6-2 Drive Pump ..................... 78 How to Remove the Drive Pump ..............78 How to Prime the Drive Pump ................. 79 How to Adjust the Pump Neutral ..............
  • Page 11 December 2023 Table of Contents Steer Axle Components ................... 101 9-1 Yoke Assembly .................... 101 How to Remove the Yoke and Drive Motor ........... 101 How to Remove a Drive Motor ..............102 9-2 Steer Cylinder ....................103 9-3 Oscillating Axle Option - GS-90 Models ............103 Non-steer Axle Components ................
  • Page 12 December 2023 Table of Contents Section 4 Fault Codes ....................... 113 Introduction ......................113 Control System Fault Codes ................114 Platform Overload Fault Codes ............... 119 Fault Code Display - Deutz Models ..............124 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 Models ... 124 How to Retrieve Active Engine Fault Codes - Deutz TD 2.2 L3, D 2.9 L4 Stage IV Models .........
  • Page 13 December 2023 Table of Contents Section 5 Schematics ......................165 Introduction ......................165 Electrical Symbols Legend ................. 166 Hydraulic Symbols Legend ................. 167 Electrical Component and Wire Color Legends ..........168 Ford Engine Relay Layout .................. 170 Electronic Control Module Layout ..............171 Electronic Control Module Pin-Out Legend ............
  • Page 14 December 2023 Table of Contents Electrical Schematics – ANSI and CSA Models ..........193 Electrical Schematic, Ford Engine Models (ANSI/CSA) ........194 Electrical Schematic, Deutz Engine Models (ANSI/CSA) ........198 Electrical Schematic, SCON (ANSI/CSA) ............201 Electrical Schematics – AS and CE Models ........... 203 Electrical Schematic, Ford Engine Models (AS/CE)...........

  • Page 15: Specifications

    December 2023 Service and Repair Manual Specifications Performance Specifications Section 2 Specific ati ons Machine Specifications Drive speed, maximum Fluid capacities Platform stowed 5 mph Hydraulic tank 30 gallons 40 ft / 5.5 sec 114 liters 8 km/h 37.5 gallons Hydraulic system (including tank) 12.2 m / 5.5 sec GS-3390...

  • Page 16: Hydraulic Oil Specifications

    Service and Repair Manual December 2023 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 17 December 2023 Service and Repair Manual Specifications Chevron Rando HD Premium Oil Chevron 5606A Hydraulic Oil MV Fluid Properties Fluid Properties ISO Grade ISO Grade Viscosity index, maximum Viscosity index, maximum Kinematic Viscosity, maximum Kinematic Viscosity, maximum cSt @ 200°F / 100°C cSt @ 200°F / 100°C cSt @ 104°F / 40°C 33.5...

  • Page 18: Hydraulic Component Specifications

    Service and Repair Manual December 2023 Specifications Shell Tellus S4 VX Fluid Hydraulic Component Properties Specifications ISO Grade Drive Pump Viscosity index, maximum Type: bi-directional variable displacement piston pump Kinematic Viscosity, maximum Flow rate @ 2500 rpm 0 - 32.5 gpm cSt @ 200°F / 100°C 0 - 123 L/min cSt @ 104°F / 40°C...
  • Page 19 December 2023 Service and Repair Manual Specifications Function manifold Oscillate manifold (option) 2700 - 2900 psi System relief valve pressure, System relief valve pressure, 3500 psi maximum, GS-3390 186 - 200 bar maximum 241 bar System relief valve pressure, 2900 - 3100 psi Float relief valve pressure 900 psi maximum, GS-4390, GS-5390...

  • Page 20: Manifold Component Specifications

    Service and Repair Manual December 2023 Specifications Manifold Component Specifications Plug torque SAE No. 2 36 in-lbs / 4 Nm SAE No. 4 10 ft-lbs / 13 Nm SAE No. 6 14 ft-lbs / 19 Nm SAE No. 8 38 ft-lbs / 51 Nm SAE No.

  • Page 21: Ford Msg-425 Efi Engine Specifications

    December 2023 Service and Repair Manual 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 22: Deutz D2011 L03I Engine Specifications

    Service and Repair Manual December 2023 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 7.35 quarts...

  • Page 23: Deutz D436 L3I Engine Specifications

    December 2023 Service and Repair Manual Specifications Deutz D436 L3i Engine Oil viscosity requirements -22° F - 86° F / -30° C - 30° C 5W-30 (synthetic) Displacement 177 cu in -4° F - 90° F / -20° C - 32° C 10W-40 2.9 liters Above 23°...

  • Page 24: Deutz Td 2.2 L3 Engine Specifications

    Service and Repair Manual December 2023 Specifications Deutz TD 2.2 L3 Engine Deutz D436 L3i Engine, continued Starter motor Displacement 134 cu. in Current draw, normal load 140A - 200A 2.2 liters Brush length, new 0.72 in Number of cylinders 18.5 mm Bore and Stroke 3.6 x 4.3 inches...
  • Page 25 December 2023 Service and Repair Manual Specifications Oil temperature switch Installation torque 8 - 18 ft-lbs 11 - 24 Nm Temperature switch point 257°F 125°C Oil Pressure switch Installation torque 8 - 18 ft-lbs 11 - 24 Nm Pressure switch point 17.4 psi 1.2 bar Fuel requirement...

  • Page 26: Deutz D 2.9 L4 Tier Iv Engine Specifications

    Service and Repair Manual December 2023 Specifications Deutz D 2.9 L4 Tier IV Engine Engine coolant Capacity 10 quarts Displacement 177 cu in 9.4 liters 2.9 liters Fuel injection system Number of cylinders Injection pump make Bosch Bore and Stroke 3.6 x 4.3 in Injection pump pressure, 15000 psi...

  • Page 27: Deutz D 2.9 L4 Stage Iv Engine Specifications

    December 2023 Service and Repair Manual Specifications Deutz D 2.9 L4 Stage IV Engine Engine coolant Capacity 10.7 quarts Displacement 177 cu in 10.1 liters 2.9 liters Fuel injection system Number of cylinders Injection pump make Bosch Bore and Stroke 3.6 x 4.3 in Injection pump pressure, 15000 psi...

  • Page 28: Weichai Wp3.2 Engine Specifications

    Service and Repair Manual December 2023 Specifications Weichai WP3.2 Engine Fuel injection system Injection pump make Bosch Displacement 193.45 cu. in Injection pump pressure, maximum 23206 psi 3.17 liters 1750 bar Number of cylinders Fuel requirement Bore and Stroke 3.86 x 4.13 in For fuel requirements, refer to the engine Operator 98 x 105 mm Manual for your engine.

  • Page 29: Hydraulic Hose And Fitting Torque Specifications

    December 2023 Service and Repair Manual 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 30: Torque Procedure

    Service and Repair Manual December 2023 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 31 December 2023 Service and Repair Manual 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 32: Repair Procedures

    Service and Repair Manual December 2023 Repair Procedures Machine Configuration: Section 3 Repair Pr oc edures 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 33 December 2023 Service and Repair Manual 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 34: Platform Controls

    Service and Repair Manual December 2023 Platform Controls Platform controls Circuit Board The platform controls, used to activate machine functions from the platform or while standing on How to R emove the Pl atform Contr ols Circ uit Board the ground, contain a printed circuit board, joystick, decal membrane pad, buttons and LEDs.

  • Page 35: Platform Components

    December 2023 Service and Repair Manual 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 R emove the Pl atform sure not to cut the power to platform wiring.
  • Page 36 Service and Repair Manual December 2023 Platform Components 20 Place a lifting strap from a second overhead 15 Remove the AC outlet box and bracket from crane under the platform at the non-steer end the platform and lay them off to the side. Do of the machine for support.

  • Page 37: Platform Extension Deck

    December 2023 Service and Repair Manual 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 R emove the Pl atform Extensi on Deck Attach a strap from the platform extension deck railings to the carriage on the forklift to How to Remove the Platform...

  • Page 38: Scissor Components

    Service and Repair Manual December 2023 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 39: Scissor Assembly, Gs-3390

    December 2023 Service and Repair Manual Scissor Components Use a soft metal drift to remove the lift cylinder rod-end pivot pin (index #12). Lower Scissor Assembly, GS-3390 the rod end of the lift cylinder down onto the number 2 inner arm (index #6). How to Dis ass embl e the Sciss or Assem bly Crushing hazard.
  • Page 40 Service and Repair Manual December 2023 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 41 December 2023 Service and Repair Manual Scissor Components 25 Lower the number 1 outer arm (index #16) 36 Place a rod through the cable tray pivot pin and twist to remove the pin. Lower the cable onto the block. tray onto the number 1 inner arm (index #8). Crushing hazard.
  • Page 42 Service and Repair Manual December 2023 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 43: How To Disassemble A Scissor Arm Pair

    December 2023 Service and Repair Manual Scissor Components How to Disassemble a Scissor How to Dis ass embl e a Sciss or 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 44 Service and Repair Manual December 2023 Scissor Components Non-steer End Steer End 1 Platform centering link 13 Number 1 pivot pin (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 45: Scissor Assembly, Gs-4390

    December 2023 Service and Repair Manual 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 Dis ass embl e the Sciss or Assem bly Remove the pin retaining fasteners from both How to Disassemble the Scissor...
  • Page 46 Service and Repair Manual December 2023 Scissor Components 14 Use a soft metal drift to remove the lift 21 Remove the cables from the number 3 inner cylinder rod-end pivot pin (index #17). Lower arm (index #18) and lay the cables off to the the rod end of the lift cylinder down.
  • Page 47 December 2023 Service and Repair Manual 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 48 Service and Repair Manual December 2023 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 49: How To Disassemble A Scissor Arm Pair

    December 2023 Service and Repair Manual Scissor Components How to Disassemble a Scissor How to Dis ass embl e a Sciss or 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 50 Service and Repair Manual December 2023 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 51 December 2023 Service and Repair Manual 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 pin (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 52: Scissor Assembly, Gs-5390

    Service and Repair Manual December 2023 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 Dis ass embl e the Sciss or Assem bly Attach a lifting strap from an overhead crane How to Disassemble the Scissor...
  • Page 53 December 2023 Service and Repair Manual 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 54 Service and Repair Manual December 2023 Scissor Components 37 Attach a lifting strap from an overhead crane 30 Carefully lower the rod end of the lower lift to the number 3 inner and outer arms (index cylinder onto the engine cover. #8 and #23) at the steer end of the machine.
  • Page 55 December 2023 Service and Repair Manual 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 56 Service and Repair Manual December 2023 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 57: How To Disassemble A Scissor Arm Pair

    December 2023 Service and Repair Manual Scissor Components How to Disassemble a Scissor How to Dis ass embl e a Sciss or 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 58: Wear Pads

    Service and Repair Manual December 2023 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 Platform How to R eplac e the Sciss or Arm W ear Pad Remove the external snap rings from both center pivot pins.

  • Page 59: How To Replace The Chassis Scissor Arm Wear Pads

    December 2023 Service and Repair Manual Scissor Components How to Replace the Chassis How to R eplac e the C has sis Sciss or Arm W ear Pads Remove the pin retaining fasteners from each platform slide block pivot pin. Do not remove Scissor Arm Wear Pads the pins.
  • Page 60 Service and Repair Manual December 2023 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 61: Lift Cylinders

    December 2023 Service and Repair Manual 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 62 Service and Repair Manual December 2023 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 63: How To Remove The Lift Cylinder - Gs-5390

    December 2023 Service and Repair Manual Scissor Components How to Remove the Lift Cylinder - How to R emove 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.
  • Page 64 Service and Repair Manual December 2023 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 65: Height Angle Sensor

    December 2023 Service and Repair Manual Scissor Components Remove the retaining fasteners securing the angle sensor mount to the sensor housing. Height Angle Sensor Remove the sensor assembly and set aside. How to Replace the Height Angle How to R eplac e the H eight Angl e Sens or Sensor Start the engine from the ground controls and raise the platform approximately 18 feet /...

  • Page 66: Engines

    Service and Repair Manual December 2023 Engines Flex Plate RPM Adjustment The flex plate acts as a coupler between the Deutz D2011L03i: 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 67: How To Remove The Flex Plate - Deutz, Weichai Models

    December 2023 Service and Repair Manual Engines How to Remove the Flex Plate - How to R emove the Flex Pl ate - D eutz, W eic hai M odels Remove the exhaust pipe, located between the exhaust manifold and muffler, from the Deutz, Weichai Models machine.

  • Page 68: How To Install The Flex Plate

    Service and Repair Manual December 2023 Engines How to Install the Flex Plate Install the pump coupler onto the pump shaft How to Ins tall the Fl ex Plate with the set screw toward the pump. Leave Install the flex plate onto the engine flywheel the appropriate gap between coupler and with the raised spline towards the pump.

  • Page 69: Ford Msg-425 Engine Fault Codes

    December 2023 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 70: Engine Fault Codes - Deutz Td 2.2 L3 Models

    Service and Repair Manual December 2023 Engines Engine Fault Codes - Engine Fault Codes - Deutz TD 2.2 L3 Models Deutz D 2.9 L4, Weichai WP3.2 Models How to Retrieve Engine Fault Codes How to Retrieve Engine Fault Codes The ECM constantly monitors the engine by the use of sensors on the engine.

  • Page 71: Diesel Particle Filter Regeneration - Deutz Td 2.2 L3

    December 2023 Service and Repair Manual Engines Diesel Particle Filter Regeneration - Deutz TD 2.2 L3 Engine The combustion of diesel fuel results in soot, which is separated in the diesel particle filter (DPF). This must be regenerated as the contamination with soot increases.

  • Page 72: Ground Controls

    Service and Repair Manual December 2023 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 73: How To Determine The Revision Level

    December 2023 Service and Repair Manual Ground Controls How to Determine the Revision How to D etermine the R evision 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 74: How To Adjust The High Torque Drive Speed

    Service and Repair Manual December 2023 Ground Controls How to Adjust the High Torque How to Adj ust the High T orque 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 75: How To Adjust The Raised Drive Speed

    December 2023 Service and Repair Manual Ground Controls How to Adjust the Raised Drive How to Adj ust the Rais ed 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 76 Service and Repair Manual December 2023 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 77: How To Adjust The Lift Speed

    December 2023 Service and Repair Manual Ground Controls How to Adjust the Lift Speed How to Adj ust 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 78: How To Adjust The Platform Lower Speed

    Service and Repair Manual December 2023 Ground Controls How to Adjust the Platform Lower How to Adj ust the Pl atform Low er 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 79: How To Adjust The Platform Settling Speed

    December 2023 Service and Repair Manual Ground Controls How to Adjust the Platform How to Adj ust the Pl atform 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 80: How To Adjust The Steer Speed

    Service and Repair Manual December 2023 Ground Controls How to Adjust the Steer Speed How to Adj ust 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 81 December 2023 Service and Repair Manual 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 82 Service and Repair Manual December 2023 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 83 December 2023 Service and Repair Manual 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 84 Service and Repair Manual December 2023 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 85: Level Sensor - Models Without Outriggers

    December 2023 Service and Repair Manual 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 86 Service and Repair Manual December 2023 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 87: Level Sensor - Models With Outriggers

    December 2023 Service and Repair Manual Ground Controls How to Install the Outrigger Level How to Ins tall and Cali brate the Level Sens or - M odels wi th Outriggers Level Sensor - Models with Sensor - Models with Outriggers Outriggers Tip-over hazard.
  • Page 88 Service and Repair Manual December 2023 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 89 December 2023 Service and Repair Manual 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 90 Service and Repair Manual December 2023 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 / Result: The platform stops raising and the tilt 5 m.
  • Page 91 December 2023 Service and Repair Manual 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 92 Service and Repair Manual December 2023 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 93 December 2023 Service and Repair Manual Hydraulic Pump How to Prime the Drive Pump How to Adjust the Pump Neutral How to Prime the Driv e Pum p How to Adj ust the Pump Neutr al Models with Eaton Pumps: Component damage hazard.
  • Page 94 Service and Repair Manual December 2023 Hydraulic Pump Turn the adjustment screw in a clockwise direction to a position halfway between the positions noted in steps 7 and 8. 10 While holding the adjustment screw in position, tighten the adjustment screw locknut. Torque to 9-11 ft-lbs / 12-15 Nm.
  • Page 95 December 2023 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 96 Service and Repair Manual December 2023 Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™...
  • Page 97 December 2023 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 40 - 45 ft-lbs Check valve, 5 psi / 0.3 bar Platform down circuit 54 - 61 Nm...
  • Page 98 Service and Repair Manual December 2023 Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™...
  • Page 99 December 2023 Service and Repair Manual Manifolds Traction Manifold Components The traction manifold is located under the function manifold Index Schematic Description Function Torque Item 95 - 100 ft-lbs Flow divider/combiner valve Controls flow to front and rear drive motors 129 - 135 Nm Orifice Plug, 0.043 inch / 1.1 mm Balances flow from flow...
  • Page 100 Service and Repair Manual December 2023 Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™...
  • Page 101 December 2023 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 102 Service and Repair Manual December 2023 Manifolds Note: 'alpha' callouts refer to corresponding notes on the hydraulic schematic. Note: 'alpha-numeric' callouts refer to corresponding notes on the electrical schematic. -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™...
  • Page 103 December 2023 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 104 Service and Repair Manual December 2023 Manifolds Determine the test weight for your machine. Refer to the specifications below. Valve Adjustments - Function Manifold Rated work load at full height, maximum 2500 lbs GS-3390 How to Adjust the System Relief How to Adj ust the Sy stem Reli ef Valve 1135 kg Valve...
  • Page 105 December 2023 Service and Repair Manual Manifolds How to Adjust the Steer Relief How to Adj ust the Steer R elief 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 106 Service and Repair Manual December 2023 Manifolds Valve Adjustments - Traction Manifold How to Adj ust the Charge Pres sur e R elief Valve How to Adjust the Charge Pressure Relief Valve Note: Refer to Drive Manifold Component list to locate the charge pressure relief valve.
  • Page 107 December 2023 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 108 Service and Repair Manual December 2023 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 Adj ust the Generator Voltage Result: If the reading on the multimeter is not How to Adjust the Generator...
  • Page 109 December 2023 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 110 Service and Repair Manual December 2023 Manifolds 7-11 Valve Coil Resistance Valve Coils Specification Note: The following coil resistance specifications How to Test a Coil are at an ambient temperature of 68°F / 20°C. As valve coil resistance is sensitive to changes in air A properly functioning coil provides an temperature, the coil resistance will typically electromotive force which operates the solenoid...
  • Page 111 December 2023 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 112 Service and Repair Manual December 2023 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 113 December 2023 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 114 Service and Repair Manual December 2023 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 115 December 2023 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 How to R emove the Yoke and Drive Motor Bodily injury hazard.
  • Page 116 Service and Repair Manual December 2023 Steer Axle Components How to Remove a Drive Motor How to R emove a Drive M otor Remove the retaining fasteners from the drive motor guard. Remove the drive motor guard Component damage hazard. from the yoke.
  • Page 117 December 2023 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 118 Service and Repair Manual December 2023 Steer Axle Components When the left rear or right rear wheel 'drops', the Oscillate Raised Relay K12 limit switch will relax and close its circuit, sending Terminal 30 of the Oscillate Raised relay, K12, power to the appropriate oscillating valve coil.
  • Page 119 December 2023 Service and Repair Manual Non-steer Axle Components 10-1 Remove the drive motor mounting fasteners. Drive Motor and Brake Slide the drive motor shaft out of the brake and remove the drive motor from the machine. How to R emove a Drive M otor and Brak e How to Remove a Drive Motor Remove the brake from the drive hub.
  • Page 120 Service and Repair Manual December 2023 Non-steer Axle Components 10-2 10-3 Drive Hub Oscillating Axle How to Remove a Drive Hub Refer to Repair Procedure, Oscillating Axle Option How to R emove a Drive H ub - GS-90 Models Note: When removing a hose assembly or fitting, the O-ring (if equipped) on the fitting and/or hose end must be replaced.
  • Page 121 December 2023 Service and Repair Manual Outrigger Components 11-1 Remove the outrigger cylinder mounting fasteners. Remove the outrigger cylinder from Outrigger Cylinder the machine. How to R emove an Outrigger Cyli nder (if equi pped) Crushing hazard. The outrigger cylinder may become How to Remove an Outrigger unbalanced and fall if not Cylinder (if equipped)
  • Page 122 Service and Repair Manual December 2023 Platform Overload Components Result: The red LED is on and the LCD 12-1 screen displays LOAD. Platform Overload System (if equipped) How to C alibr ate the Pl atform Overl oad System (if equipped) How to Calibrate the Platform Overload System Machines with platform overload systems, proper...
  • Page 123 December 2023 Service and Repair Manual Platform Overload Components Confirm Calibration: Fully lower the platform to the stowed position. Add additional weight to the platform. When the platform is fully stowed, Model Additional weight momentarily activate the calibration toggle 500 lbs switch in the up position to confirm.
  • Page 124 Service and Repair Manual December 2023 Platform Overload Components 12-2 Use the up or down buttons to scroll to Select Options. Platform Overload Recovery Message Press the lift function enable button. Use the up or down buttons to scroll to If the ground controls LCD screen displays Ovrld Overload Option.
  • Page 125 December 2023 Service and Repair Manual Platform Overload Components 12-3 Down Limit Height How to Calibrate the Down Limit How to C alibr ate the Dow n Limit H eight Height Note: Perform this procedure on a firm, level surface with the machine in the stowed position unless otherwise instructed.
  • Page 126 Service and Repair Manual December 2023 This page intentionally left blank. -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™ ™...

  • Page 127: Troubleshooting And Repair Procedures Shall Be Completed By A Person Trained And Qualified On The Repair Of This Machine

    December 2023 Service and Repair Manual Control System Fault Codes Before Troubleshooting: Section 4 Faul t Codes 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 128: About This Section

    Service and Repair Manual December 2023 Control System Fault Codes About This Section LED Diagnostic Readout When a malfunction is discovered, the fault code charts in this section will help a service professional pinpoint the cause of the problem. To use this section, basic hand tools and certain pieces of test equipment are required —...
  • Page 129 December 2023 Service and Repair Manual 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 130 Service and Repair Manual December 2023 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 131 December 2023 Service and Repair Manual 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 132 Service and Repair Manual December 2023 Fault Codes LOW ECU Low ECM voltage. System shutdown. Charge battery. VOLTAGE LOW ENGINE Low RPM. Engine idle RPM too Contact Genie Product low. Support. HIGH ENGINE High RPM. Engine RPM too Contact Genie Product high.
  • Page 133 December 2023 Service and Repair Manual Platform Overload Fault Codes Platform Overload Display 1 LCD screen 2 red LED The diagnostic readout displays numerical codes that provide information about height sensor, pressure sensor and platform overload malfunctions. The codes listed in the Fault Code Chart can aid in troubleshooting the machine by pinpointing the area or component affected.
  • Page 134 Service and Repair Manual December 2023 Fault Codes Error Source Error Type Condition Solution Name ID Name Height sensor 12 Value too high Output higher than • Check wiring normal. • Check 5V supply voltage • Shorted too high • Replace sensor 14 Cross check fault Height channels not •...
  • Page 135 December 2023 Service and Repair Manual Fault Codes Error Source Error Type Condition Solution Name ID Name Height sensor 12 Value too high Output higher than • Check wiring normal. (Safety) • Check 5V supply voltage • Shorted too high •...
  • Page 136 Service and Repair Manual December 2023 Fault Codes Error Source Error Type Condition Solution Name ID Name Pressure sensor 12 Value too high Output higher than • Check wiring normal. • Check 5V supply voltage • Shorted too high • Replace sensor 14 Cross check fault Pressure channels not •...
  • Page 137 December 2023 Service and Repair Manual Fault Codes Error Source Error Type Condition Solution Name ID Name SCON - Safety Primary and secondary micros in • Replace SCON controller the SCON detect an internal safety fault. 29 Software Primary and secondary •...
  • Page 138 Service and Repair Manual December 2023 Fault Code Display - Deutz Models How to Retrieve Active Engine How to R etrieve Ac tive Engi ne F ault Codes D eutz D 2.9 L4 M odels With an active fault and the engine running: (preferred method) Fault Codes - Deutz D 2.9 L4 Tier IV Models...
  • Page 139 December 2023 Service and Repair Manual Fault Code Display - Deutz Models How to Retrieve Active Engine How to R etrieve Ac tive Engi ne F ault Codes - D eutz TD 2.2 L3, D 2.9 L4 Stage IV Models With an active fault and the engine running: (preferred method) Fault Codes - Deutz TD 2.2 L3, D...
  • Page 140 Service and Repair Manual December 2023 Fault Code Display - Deutz Models Flashing and Solid LED's - Deutz D 2.9 L4 Tier IV Models Faul t Code Dis play - Flashi ng and Solid LED's - D eutz D 2.9 L4 M odels 1 Left green LED: Flashing, engine fault detected.
  • Page 141 December 2023 Service and Repair Manual Fault Code Display - Deutz Models Soft Key Functions and Icons - Deutz D 2.9 L4 Tier IV Models Soft Key F unc tions and Ic ons - Deutz D 2.9 L4 Models Next menu • Exit / Back one screen • Decrease brightness (-) Brightness / Contrast •...
  • Page 142 Service and Repair Manual December 2023 Fault Code Display - Deutz Models Soft Key Functions and Icons - Deutz TD 2.2 L3, D 2.9 L4 Stage IV Soft Key F unc tions and Ic ons - Deutz TD 2.2 L3 Models Models Exit / Back one screen Scroll up •...
  • Page 143 December 2023 Service and Repair Manual Fault Code Display - Deutz Models Main Menu Structure - Deutz D 2.9 L4 Tier IV Models Main M enu Str ucture - Deutz D 2.9 L4 Tier IV Models Part No. 1325652GT -3390 • GS -4390 •...
  • Page 144 Service and Repair Manual December 2023 Fault Code Display - Deutz Models Main Menu Structure - Deutz TD 2.2 L3 Models Main M enu Str ucture - Deutz TD 2.2 L3 Models -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™...
  • Page 145 December 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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 146 Service and Repair Manual December 2023 Deutz D 2.9 L4 Tier IV 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...
  • Page 147 December 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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...
  • Page 148 Service and Repair Manual December 2023 Deutz D 2.9 L4 Tier IV 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...
  • Page 149 December 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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 150 Service and Repair Manual December 2023 Deutz D 2.9 L4 Tier IV 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...
  • Page 151 December 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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 152 Service and Repair Manual December 2023 Deutz D 2.9 L4 Tier IV 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-...
  • Page 153 December 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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);...
  • Page 154 Service and Repair Manual December 2023 Deutz D 2.9 L4 Tier IV 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 155 December 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV 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-...
  • Page 156 Service and Repair Manual December 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1077 411 Engine exhaust gas recirculation. SPN = Suspect Parameter Number Signal value above maximum limit.
  • Page 157 December 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1134 3251 3 DPF voltage above normal or SPN = Suspect Parameter Number shorted to high.
  • Page 158 Service and Repair Manual December 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1209 157 Engine fuel injector metering rail SPN = Suspect Parameter Number pressure voltage below normal or shorted to low.
  • Page 159 December 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 1308 677 Engine starter motor relay current SPN = Suspect Parameter Number below normal or shorted to low.
  • Page 160 Service and Repair Manual December 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 1392 51 Engine throttle valve 1, position SPN = Suspect Parameter Number 1 voltage below normal or shorted to low.
  • Page 161 December 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier 3349 Timeout Error of CAN receive SPN = Suspect Parameter Number frame TSC1TR;...
  • Page 162 Service and Repair Manual December 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier Ambient air temperature sensor SPN = Suspect Parameter Number voltage above normal or shorted to high.
  • Page 163 December 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 5363 5 Engine cylinder 6 fuel injection SPN = Suspect Parameter Number quantity current below normal or open circuit.
  • Page 164 Service and Repair Manual December 2023 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN FMI Description FMI = Failure Mode Identifier 4257 14 Engine fuel 1 injector, group SPN = Suspect Parameter Number 3 missing injector adjustment value programming injector 3.
  • Page 165 December 2023 Service and Repair Manual Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes DTC = Diagnostic Trouble Code DTC SPN Description FMI = Failure Mode Identifier Actual engine percent torque. SPN = Suspect Parameter Number DFC to report the fault in energizing time comparison.
  • Page 166 Service and Repair Manual December 2023 Deutz D436 L3i Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier Functional fault, switch off Description Oil pressure switch: pressure below Revolutions / Speed switch off limit Speed sensor 1: sensor fault; distance Coolant temperature switch: exceeded from gear;...
  • Page 167 December 2023 Service and Repair Manual Deutz D436 L3i Engine Fault Codes SPN = Suspect Parameter Number FMI = Failure Mode Identifier Description Communication CAN-Bus controller: CAN controller faulty. CAN interface. SAE J1939: Overflow in input buffer. Transmission cannot be placed on bus.

  • Page 168: Electrocution/Burn Hazard

    Service and Repair Manual December 2023 Ford MSG-425 Engine Fault Codes Note: Once a fault code has been retrieved and How to Retrieve Ford Engine How to R etrieve For d Engine F ault C odes the repair has been completed, the ECM memory Fault Codes must be reset to clear the fault code from the ECM.
  • Page 169 December 2023 Service and Repair Manual 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 170 Service and Repair Manual December 2023 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 171 December 2023 Service and Repair Manual 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 172 Service and Repair Manual December 2023 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 173 December 2023 Service and Repair Manual 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 2315 Primary Loop Open or Low-side Short to Ground 2316...
  • Page 174 Service and Repair Manual December 2023 Fault Code Display - Weichai Models How to Retrieve Active Engine How to R etrieve Ac tive Engi ne F ault Codes - W eichai W P3.2 M odels With an active fault and the engine running: (preferred method) Fault Codes - Weichai WP3.2 Models...
  • Page 175 December 2023 Service and Repair Manual Fault Code Display - Weichai Models Main Menu Structure - Weichai WP3.2 Models Main M enu Str ucture - Weic hai WP3.2 M odels Any Soft Key Main Menu Scroll Up Scroll Down Note: Use the Scroll Main Menu Up/Down buttons.
  • Page 176 Service and Repair Manual December 2023 Weichai WP3.2 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier SRC high for battery Description SRC low for battery Vehicle speed 1 above max. Oil temperature sensor voltage above threshold max.
  • Page 177 December 2023 Service and Repair Manual Weichai WP3.2 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 1416 Engine Speed Sensor #1: Voltage Description Below Normal 1414 Injector 2 high-side short circuited to 1416 Injector 4 open circuit low-side 1416 Cylinder 4 and other cylinders in the...
  • Page 178 Service and Repair Manual December 2023 Weichai WP3.2 Engine Fault Codes SPN = Suspect Parameter Number Description FMI = Failure Mode Identifier 4201 Camshaft period error Description 4201 Camshaft synchronization error 1418 Injector 6 high-side short circuited to 4201 Camshaft period error low-side 4201 Camshaft and crankshaft...
  • Page 179 December 2023 Service and Repair Manual Schematics About This Section Section 5 Schem atics 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.
  • Page 180 Service and Repair Manual December 2023 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 181 December 2023 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 182 Service and Repair Manual December 2023 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 183 December 2023 Service and Repair Manual Electrical Component and Wire Color Legends Item Description Wire Color Legend 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 184 Service and Repair Manual December 2023 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 10 Fuse 6 - 10A, Alternator...
  • Page 185 December 2023 Service and Repair Manual Electronic Control Module Layout X - X 1 drive pump 9 ECM - Electronic Control Module 2 engine 10 level sensor 3 outriggers 11 horn 4 pressure sensor 12 ground controls 5 angle sensor 13 function manifold 6 SCON 14 drive manifold...
  • Page 186 Service and Repair Manual December 2023 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 187 December 2023 Service and Repair Manual Electronic Control Module Pin-Out Legend Oscillate raised relay CR85 terminal 86 (output) Ground (output) Oscillate stowed relay CR84 terminal 86 (output) Plug Auxiliary down relay CR23 terminal 87 (output) J2 Connector Flashing beacons FS1 (output) Description ECM power (input) SCON (input)
  • Page 188 Service and Repair Manual December 2023 Ground Controls Wiring Panel Layout K1 1st E-Stop K6 Auxiliary down K16 Coil cutout K2 2nd E-Stop K8 Oil cooler (option) K77 up interrupt K3 Starter K11 Oscillate stowed (option) K78 down interrupt K4 Ignition K12 Oscillate elevated (option) K102 Telematics K5 Horn...
  • Page 189 December 2023 Service and Repair Manual Wiring Diagram - Platform Control Box Part No. 1325652GT -3390 • GS -4390 • GS -5390 ™ ™ ™...
  • Page 190 Service and Repair Manual December 2023 Limit Switch Legend 1 outrigger deployed (all models) • left front LS12 • right front LS13 • left rear LS14 • right rear LS15 1 outrigger deployed (GS-5390 CE models) (lower) • left front LS12A •...
  • Page 191 December 2023 Service and Repair Manual Wiring Diagram - 12 kW Hydraulic Generator (option) Part No. 1325652GT -3390 • GS -4390 • GS -5390 ™ ™ ™...
  • Page 192 Service and Repair Manual December 2023 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 193 December 2023 Service and Repair Manual Ford MSG-425 Engine Wire Harness...
  • Page 194 Service and Repair Manual December 2023 Ford MSG-425 EFI Engine Wire Harness -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™ ™...
  • Page 195 December 2023 Service and Repair Manual Deutz D 2.9 L4 Tier IV Engine Wire Harness F8 30A C2-4 C2-2 C2-3 C2-5 C2-6 C2-1 P20PWR RD-14 02GND BR-14 P20PWR RD-14 02GND BR-14 FUEL PUMP P20PWR RD-14 02GND BR-14 F20 20A C26LVL WH/RD C1-3 R135 PWR WH CLSWJPR BK/WH...
  • Page 196 Service and Repair Manual December 2023 Deutz D 2.9 L4 Tier IV Engine Wire Harness...
  • Page 197 December 2023 Service and Repair Manual Deutz D 2.9 L4 Stage IV Engine Wire Harness...
  • Page 198 Service and Repair Manual December 2023 Deutz D 2.9 L4 Stage IV Engine Wire Harness CR1B P134PWR RD GND BR D81CAN- GR D82CAN+ YL FUEL PUMP RELAY P20PWR RD P109_7_12V OR P109_7_12V RD C135PWR BL/WH C135RET BL/RD R135PWR BL R27AUX GR NEUTRAL C34RET BK/WH CLUTCH...
  • Page 199 December 2023 Service and Repair Manual Deutz D 2.9 L4 Stage IV Engine Wire Harness ENGINE INTERFACE CONNECTOR C16 (DIAGNOSTIC) P134PWR RD P134PWR RD GND BR GND BR D81CAN- GR D81CAN- GR D82CAN+ YL D104CAN- GR D105CAN+ YL D82CAN+ YL 120Ω...
  • Page 200 Service and Repair Manual December 2023 Deutz D 2.9 L4 Stage IV Engine Wire Harness...
  • Page 201 December 2023 Service and Repair Manual Deutz TD 2.2 L3 Engine Wire Harness...
  • Page 202 Service and Repair Manual December 2023 Deutz TD 2.2 L3 Engine Wire Harness P134PWR RD GND BR D81CAN- GR D82CAN+ YL FUEL PUMP RELAY P20PWR RD P109_7_12V OR P109_7_12V RD C135PWR BL/WH C135RET BL/RD R135PWR BL R27AUX GN NEUTRAL C34RET BK/WH CLUTCH RELAY R34SA RD...
  • Page 203 December 2023 Service and Repair Manual Deutz TD 2.2 L3 Engine Wire Harness ENGINE INTERFACE CONNECTOR C16 (DIAGNOSTIC) P134PWR RD P134PWR RD GND BR GND BR ENGINE AFTER TREATMENT D81CAN- GR D81CAN- GR D82CAN+ YL D104CAN- GR D105CAN+ YL D82CAN+ YL 120Ω...
  • Page 204 Service and Repair Manual December 2023 Deutz TD 2.2 L3 Engine Wire Harness...
  • Page 205 December 2023 Service and Repair Manual Weichai WP3.2 Engine Wire Harness C37 (DIAGNOSTIC) P134PWR RD P134PWR RD GND BR GND BR D81CAN- GR D81CAN- GR D104CAN- GR D82CAN+ YL D105CAN+ YL D82CAN+ YL R135PWR BL P21PWR RD P21PWR RD V_V_5VFSS P21PWR RD I_F_FSS FAN SPEED SENSOR(NOT USED)
  • Page 206 Service and Repair Manual December 2023 Weichai WP3.2 Engine Wire Harness...
  • Page 207 December 2023 Service and Repair Manual Electrical Schematic, Ford Engine Models (ANSI/CSA)
  • Page 208 Service and Repair Manual December 2023 Electrical Schematic, Ford Engine Models (ANSI/CSA) FUEL LEVEL SENSOR FUEL TANK -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™ ™...
  • Page 209 December 2023 Service and Repair Manual Electrical Schematic, Ford Engine Models (ANSI/CSA) BN25 FUNCTION ENABLE RIGHT STEER LEFT HALL EFFECT GENERATOR HALL EFFECT GENERATOR Part No. 1325652GT -3390 • GS -4390 • GS -5390 ™ ™ ™...
  • Page 210 Service and Repair Manual December 2023 Electrical Schematic, Ford Engine Models (ANSI/CSA)
  • Page 211 December 2023 Service and Repair Manual Electrical Schematic, Deutz Engine Models (ANSI/CSA)
  • Page 212 Service and Repair Manual December 2023 Electrical Schematic, Deutz Engine Models (ANSI/CSA) PLAT CHASSIS K102 REMOTE SCON DISABLE RELAY CONN FUEL LEVEL SENSOR FUEL TANK -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™ ™...
  • Page 213 December 2023 Service and Repair Manual Electrical Schematic, Deutz Engine Models (ANSI/CSA) BN25 FUNCTION ENABLE RIGHT STEER LEFT HALL EFFECT GENERATOR 2 SEC HALL EFFECT GENERATOR Part No. 1325652GT -3390 • GS -4390 • GS -5390 ™ ™ ™...
  • Page 214 Service and Repair Manual December 2023 Electrical Schematic, Deutz Engine Models (ANSI/CSA)

  • Page 215: Electrical Schematics

    December 2023 Service and Repair Manual Electrical Schematic, SCON (ANSI/CSA) BR GND BR GND GROUND P134 P134 POWER GR WH SCON CAN0 GR BK CAN0 WH RD P100 RD WH C145 CALIBRATION SW -2 P109 CHASSIS SENSOR POWER RD BK P110 SENSOR GROUND ANGLE SENSOR HIGH...
  • Page 216 Service and Repair Manual December 2023 Electrical Schematic, SCON (ANSI/CSA)
  • Page 217 December 2023 Service and Repair Manual Electrical Schematic, Ford Engine Models (AS/CE)
  • Page 218 Service and Repair Manual December 2023 Electrical Schematic, Ford Engine Models (AS/CE) FUEL LEVEL SENSOR J1-C7 J2-C10 J1-B12 J2-B9 -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™ ™...
  • Page 219 December 2023 Service and Repair Manual Electrical Schematic, Ford Engine Models (AS/CE) BN25 FUNCTION ENABLE RIGHT STEER LEFT HALL EFFECT GENERATOR HALL EFFECT GENERATOR Part No. 1325652GT -3390 • GS -4390 • GS -5390 ™ ™ ™...
  • Page 220 Service and Repair Manual December 2023 Electrical Schematic, Ford Engine Models (AS/CE)
  • Page 221 December 2023 Service and Repair Manual Electrical Schematic, Deutz and Weichai Engine Models (AS/CE)
  • Page 222 Service and Repair Manual December 2023 Electrical Schematic, Deutz and Weichai Engine Models (AS/CE) SERVICE PORT DISPLAY 8 CHAR PLAT ENGINE CAN SCON CAN CONNECTOR CONNECTOR CHASSIS FUEL LEVEL CAN COMM MODULE 200 / LEVEL SENSOR FUEL LEVEL SENSOR RD WH YL WH BK WH J1-C7...
  • Page 223 December 2023 Service and Repair Manual Electrical Schematic, Deutz and Weichai Engine Models (AS/CE) BN25 FUNCTION ENABLE RIGHT STEER LEFT HALL EFFECT GENERATOR 2 SEC HALL EFFECT GENERATOR Part No. 1325652GT -3390 • GS -4390 • GS -5390 ™ ™ ™...
  • Page 224 Service and Repair Manual December 2023 Electrical Schematic, Deutz and Weichai Engine Models (AS/CE)
  • Page 225 December 2023 Service and Repair Manual Electrical Schematic, SCON (AS/CE) BR GND BR GND GROUND P134 P134 POWER GR WH SCON CAN0 GR BK CAN0 WH RD P100 RD WH C145 CALIBRATION SW -2 P109 CHASSIS SENSOR POWER RD BK P110 SENSOR GROUND ANGLE SENSOR HIGH...
  • Page 226 Service and Repair Manual December 2023 Electrical Schematic, SCON (AS/CE)
  • Page 227 December 2023 Service and Repair Manual Hydraulic Schematic...
  • Page 228 Service and Repair Manual December 2023 Hydraulic Schematic -3390 • GS -4390 • GS -5390 Part No. 1325652GT ™ ™ ™...
  • Page 229 December 2023 Service and Repair Manual Hydraulic Schematic Part No. 1325652GT -3390 • GS -4390 • GS -5390 ™ ™ ™...
  • Page 230 Service and Repair Manual December 2023 Hydraulic Schematic GS™- 3390 • GS™-4390 • GS™-5390 Part No. 1325652GT Servic e and R epair M anual Decem ber 2023...

This manual is also suitable for:

Genie gs-4390Genie gs-5390Genie gs-3390Gs90m-101

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