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Genie GS-3384 GS-3390 GS-4390 GS-5390 Service & Repair Manual – PDF
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Genie GS-3384 GS-3390 GS-4390 GS-5390 Service & Repair Manual 1272222 – PDF DOWNLOAD
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Description
Genie GS-3384 GS-3390 GS-4390 GS-5390 Service & Repair Manual 1272222 – PDF DOWNLOAD
Language : English
Pages : 213
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GS-3384 GS-3390 GS-4390 GS-5390 Service & Repair Manual 1272222 – PDF DOWNLOAD
Front Cover........................................................................................................................... 1 Important Information................................................................................................................. 2 Revision History...................................................................................................................... 3 Serial Number Legend.................................................................................................................. 4 General Safety Rules.................................................................................................................. 5 Table of Contents..................................................................................................................... 7 Specifications........................................................................................................................ 15 Machine Specifications............................................................................................................ 15 Performance Specifications........................................................................................................ 16 Hydraulic Oil Specifications...................................................................................................... 17 Hydraulic Component Specifications................................................................................................ 20 Manifold Component Specifications................................................................................................. 21 Ford MSG-425 EFI Engine Specifications............................................................................................ 22 Deutz D2011 L03i Engine Specifications............................................................................................ 23 Deutz D 2.9 L4 Engine Specifications.............................................................................................. 24 Hydraulic Hose and Fitting Torque Specifications.................................................................................. 26 Torque Procedure.................................................................................................................. 27 Repair Procedures..................................................................................................................... 29 Introduction...................................................................................................................... 29 Platform Controls................................................................................................................. 31 1-1 Circuit Board............................................................................................................. 31 How to Remove the Platform Controls Circuit Board......................................................................... 31 Platform Components............................................................................................................... 32 2-1 Platform.................................................................................................................. 32 How to Remove the Platform................................................................................................ 32 2-2 Platform Extension Deck................................................................................................... 34 How to Remove the Platform Extension Deck................................................................................. 34 Scissor Components................................................................................................................ 35 3-1 Scissor Assembly, GS-3384 and GS-3390..................................................................................... 36 How to Disassemble the Scissor Assembly................................................................................... 36 How to Disassemble a Scissor Arm Pair..................................................................................... 40 3-2 Scissor Assembly, GS-4390................................................................................................. 42 How to Disassemble the Scissor Assembly................................................................................... 42 How to Disassemble a Scissor Arm Pair..................................................................................... 46 3-3 Scissor Assembly, GS-5390................................................................................................. 49 How to Disassemble the Scissor Assembly................................................................................... 49 How to Disassemble a Scissor Arm Pair..................................................................................... 54 3-4 Wear Pads................................................................................................................. 55 How to Replace the Scissor Arm Wear Pad................................................................................... 55 How to Replace the Chassis Scissor Arm Wear Pads.......................................................................... 56 3-5 Lift Cylinders............................................................................................................ 58 How to Remove the Lift Cylinder - GS-3384, GS-3390 and GS-4390............................................................ 58 How to Remove the Lift Cylinder - GS-5390................................................................................. 60 Engines........................................................................................................................... 62 4-1 RPM Adjustment............................................................................................................ 62 4-2 Flex Plate................................................................................................................ 62 How to Remove the Flex Plate - Ford Models................................................................................ 62 How to Remove the Flex Plate - Deutz Models............................................................................... 63 How to Install the Flex Plate............................................................................................. 64 4-3 Ford MSG-425 Engine Fault Codes........................................................................................... 65 4-4 Engine Fault Codes - Deutz D 2.9 L4 and Perkins 404F-22 Models............................................................ 66 Ground Controls................................................................................................................... 67 5-1 Auxiliary Platform Lowering............................................................................................... 67 5-2 Controller Adjustments.................................................................................................... 67 How to Determine the Revision Level....................................................................................... 68 How to Adjust the Stowed Drive Speed...................................................................................... 68 How to Adjust the High Torque Drive Speed................................................................................. 69 How to Adjust the Raised Drive Speed...................................................................................... 70 How to Adjust the Lift Speed.............................................................................................. 72 How to Adjust the Platform Lower Speed.................................................................................... 73 How to Adjust the Platform Settling Speed................................................................................. 74 How to Adjust the Steer Speed............................................................................................. 75 5-3 Software Configuration.................................................................................................... 75 5-4 Level Sensor - Models without Outriggers.................................................................................. 80 How to Install and Calibrate the Level Sensor - Models without Outriggers................................................. 80 5-5 Level Sensor - Models with Outriggers..................................................................................... 82 How to Install and Calibrate the Level Sensor - Models with Outriggers.................................................... 82 Hydraulic Pump.................................................................................................................... 86 6-1 Lift/Steer Pump........................................................................................................... 86 How to Remove the Lift/Steer Pump......................................................................................... 86 6-2 Drive Pump................................................................................................................ 87 How to Remove the Drive Pump.............................................................................................. 87 How to Prime the Pump..................................................................................................... 88 How to Adjust the Pump Neutral............................................................................................ 89 Manifolds......................................................................................................................... 91 7-1 Function Manifold Components - Models with Outriggers..................................................................... 91 7-2 Function Manifold Components - Models without Outriggers.................................................................. 93 7-3 Traction Manifold Components.............................................................................................. 95 7-4 Oscillate Manifold Components, GS-90 (option)............................................................................. 97 7-5 Welder Manifold Components (option)....................................................................................... 99 7-6 Valve Adjustments - Function Manifold.....................................................................................100 How to Adjust the System Relief Valve.....................................................................................100 How to Adjust the Steer Relief Valve......................................................................................101 7-7 Valve Adjustments - Traction Manifold.....................................................................................102 How to Adjust the Charge Pressure Relief Valve............................................................................102 7-8 Generator Manifold Components.............................................................................................103 7-9 Valve Adjustments - Generator Manifold....................................................................................104 How to Adjust the Generator Voltage.......................................................................................104 7-10 Generator Relief Valve Manifold Components...............................................................................105 7-11 Valve Coils..............................................................................................................106 Fuel and Hydraulic Tanks..........................................................................................................108 8-1 Fuel Tank.................................................................................................................108 8-2 Hydraulic Tank............................................................................................................109 Steer Axle Components.............................................................................................................111 9-1 Yoke Assembly.............................................................................................................111 How to Remove the Yoke and Drive Motor....................................................................................111 How to Remove a Drive Motor...............................................................................................112 9-2 Steer Cylinder............................................................................................................113 9-3 Oscillating Axle Option - GS-90 Models....................................................................................113 Non-steer Axle Components.........................................................................................................115 10-1 Drive Motor and Brake....................................................................................................115 How to Remove a Drive Motor and Brake.....................................................................................115 10-2 Drive Hub................................................................................................................116 How to Remove a Drive Hub.................................................................................................116 10-3 Oscillating Axle.........................................................................................................117 Outrigger Components..............................................................................................................118 11-1 Outrigger Cylinder.......................................................................................................118 How to Remove an Outrigger Cylinder (if equipped).........................................................................118 Platform Overload Components......................................................................................................119 12-1 Platform Overload System (if equipped)...................................................................................119 How to Calibrate the Platform Overload System (if equipped)...............................................................119 12-2 Platform Overload Recovery Message (software version B3 and later).......................................................128 Fault Codes...........................................................................................................................130 Introduction......................................................................................................................130 Control System Fault Codes........................................................................................................132 Fault Code Display - Deutz Models.................................................................................................136 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 Models...............................................................136 Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 Models.........................................................137 Soft Key Functions and Icons - Deutz D 2.9 L4 Models..........................................................................138 Main Menu Structure - Deutz D 2.9 L4 Models...................................................................................139 Deutz D 2.9 L4 Engine Fault Codes.................................................................................................140 Ford MSG-425 Engine Fault Codes...................................................................................................151 How to Retrieve Ford Engine Fault Codes.......................................................................................151 How to Clear Engine Fault Codes from the ECM..................................................................................151 Ford MSG-425 Engine Fault Codes...............................................................................................152 Schematics............................................................................................................................157 Introduction......................................................................................................................157 Electrical Symbols Legend.........................................................................................................158 Hydraulic Symbols Legend..........................................................................................................159 Electrical Component and Wire Color Legends.......................................................................................160 Ford Engine Relay Layout..........................................................................................................162 Electronic Control Module Layout..................................................................................................163 Electronic Control Module Pin-Out Legend..........................................................................................164 Ground Controls Wiring Panel Layout...............................................................................................166 Wiring Diagram - Platform Control Box.............................................................................................167 Limit Switch Legend...............................................................................................................168 Wiring Diagram - 12 kW Hydraulic Generator (option)...............................................................................169 Electrical Schematics - Engine Harness............................................................................................171 Ford MSG-425 EFI Engine Wire Harness..........................................................................................172 Deutx D 2.9 L4 Engine Wire Harness............................................................................................173 Hydraulic Schematics..............................................................................................................175 Hydraulic Schematic, To Serial Numbers GS8415-42316 and GS9015-50184..........................................................176 Hydraulic Schematic, From Serial Numbers GS84154-42317 and GS9015-50185.......................................................178 Electrical Schematics – ANSI and CSA Models.......................................................................................181 Electrical Schematic, Ford Engine Models (ANSI/CSA) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948)..............182 Electrical Schematic, Ford Engine Models (ANSI/CSA) (from GS84F-45672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081).....183 Electrical Schematic, Ford Engine Models (ANSI/CSA) (from GS84F-45681, GS90D-2862, GS90F-55082)...............................186 Platform Controls, Ford Engine Models (ANSI/CSA)..............................................................................187 Electrical Schematic, Deutz Engine Models (ANSI/CSA) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948).............190 Electrical Schematic, Deutz Engine Models (ANSI/CSA) (from GS84F-45672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081)....191 Electrical Schematic, Deutz Engine Models (ANSI/CSA) (from GS84F-45681, GS90D-2862, GS90F-55082)..............................194 Platform Controls, Deutz Engine Models (ANSI/CSA).............................................................................195 Electrical Schematics – AS and CE Models..........................................................................................197 Electrical Schematic, Ford Engine Models (AS/CE) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948).................198 Electrical Schematic, Ford Engine Models (AS/CE) (from GS84F-54672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081)........199 Electrical Schematic, Ford Engine Models (AS/CE) (from GS84F-45681, GS90D-2862, GS90F-55082)..................................202 Platform Controls, Ford Engine Models (AS/CE).................................................................................203 Electrical Schematic, Deutz Engine Models (AS/CE) (from GS84D-101) • (to GS84F-45671, GS90D-2776, GS90F-54948)................206 Electrical Schematic, Deutz Engine Models (AS/CE) (from GS84F-45672 to 45680, GS90D-2777 to 2861, GS90F-54949 to 55081).......207 Electrical Schematic, Deutz Engine Models (AS/CE) (from GS84F-45681, GS90D-2862, GS90F-55082).................................210 Platform Controls, Deutz Engine Models (AS/CE)................................................................................211 Back Cover............................................................................................................................213
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