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Genie GS-3384 to GS-5390 Service Repair Manual PDF Download
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Genie GS-3384 GS-3390 GS-4390 GS-5390 Service & Repair Manual 1306587 – PDF DOWNLOAD
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Description
Genie GS-3384 GS-3390 GS-4390 GS-5390 Service & Repair Manual 1306587 – PDF DOWNLOAD
Language : English
Pages : 237
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GS-3384 GS-3390 GS-4390 GS-5390 Service & Repair Manual 1306587 – PDF DOWNLOAD
Front Cover...................................................................................... 1 Important Information............................................................................ 2 Find a Manual for this Model..................................................................... 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........................................................... 19 Manifold Component Specifications............................................................ 20 Ford MSG-425 EFI Engine Specifications....................................................... 21 Deutz D2011 L03i Engine Specifications....................................................... 22 Deutz D436 L3i Engine Specifications......................................................... 23 Deutz TD 2.2 L3 Engine Specifications........................................................ 24 Deutz D 2.9 L4 Tier IV Engine Specifications................................................. 26 Deutz D 2.9 L4 Stage IV Engine Specifications................................................ 27 Weichai WP3.2 Engine Specifications.......................................................... 28 Hydraulic Hose and Fitting Torque Specifications............................................. 29 Torque Procedure............................................................................. 30 Repair Procedures................................................................................ 32 Introduction................................................................................. 32 Platform Controls............................................................................ 34 1-1 Circuit Board........................................................................ 34 How to Remove the Platform Controls Circuit Board.................................... 34 Platform Components.......................................................................... 35 2-1 Platform............................................................................. 35 How to Remove the Platform........................................................... 35 2-2 Platform Extension Deck.............................................................. 37 How to Remove the Platform Extension Deck............................................ 37 Scissor Components........................................................................... 38 3-1 Scissor Assembly, GS-3384 and GS-3390................................................ 39 How to Disassemble the Scissor Assembly.............................................. 39 How to Disassemble a Scissor Arm Pair................................................ 43 3-2 Scissor Assembly, GS-4390............................................................ 45 How to Disassemble the Scissor Assembly.............................................. 45 How to Disassemble a Scissor Arm Pair................................................ 49 3-3 Scissor Assembly, GS-5390............................................................ 52 How to Disassemble the Scissor Assembly.............................................. 52 How to Disassemble a Scissor Arm Pair................................................ 57 3-4 Wear Pads............................................................................ 58 How to Replace the Scissor Arm Wear Pad.............................................. 58 How to Replace the Chassis Scissor Arm Wear Pads..................................... 59 3-5 Lift Cylinders....................................................................... 61 How to Remove the Lift Cylinder - GS-3384, GS-3390 and GS-4390....................... 61 How to Remove the Lift Cylinder - GS-5390............................................ 63 3-6 Height Angle Sensor.................................................................. 65 How to Replace the Height Angle Sensor............................................... 65 Engines...................................................................................... 66 4-1 RPM Adjustment....................................................................... 66 4-2 Flex Plate........................................................................... 66 How to Remove the Flex Plate - Ford Models........................................... 66 How to Remove the Flex Plate - Deutz, Weichai Models................................. 67 How to Install the Flex Plate........................................................ 68 4-3 Ford MSG-425 Engine Fault Codes...................................................... 69 4-4 Engine Fault Codes - Deutz TD 2.2 L3 Models.......................................... 70 4-5 Engine Fault Codes - Deutz D 2.9 L4, Weichai WP3.2 Models............................ 70 4-6 Diesel Particle Filter Regeneration - Deutz TD 2.2 L3................................ 71 Ground Controls.............................................................................. 72 5-1 Auxiliary Platform Lowering.......................................................... 72 5-2 Controller Adjustments............................................................... 72 How to Determine the Revision Level.................................................. 73 How to Adjust the Stowed Drive Speed................................................. 73 How to Adjust the High Torque Drive Speed............................................ 74 How to Adjust the Raised Drive Speed................................................. 75 How to Adjust the Lift Speed......................................................... 77 How to Adjust the Platform Lower Speed............................................... 78 How to Adjust the Platform Settling Speed............................................ 79 How to Adjust the Steer Speed........................................................ 80 5-3 Software Configuration............................................................... 80 5-4 Level Sensor - Models without Outriggers............................................. 85 How to Install and Calibrate the Level Sensor - Models without Outriggers............ 85 5-5 Level Sensor - Models with Outriggers................................................ 87 How to Install and Calibrate the Level Sensor - Models with Outriggers............... 87 Hydraulic Pump............................................................................... 91 6-1 Lift/Steer Pump...................................................................... 91 How to Remove the Lift/Steer Pump.................................................... 91 6-2 Drive Pump........................................................................... 92 How to Remove the Drive Pump......................................................... 92 How to Prime the Drive Pump.......................................................... 93 How to Adjust the Pump Neutral....................................................... 93 Manifolds.................................................................................... 95 7-1 Function Manifold Components - Models with Outriggers................................ 95 7-2 Function Manifold Components - Models without Outriggers............................. 97 7-3 Traction Manifold Components......................................................... 99 7-4 Oscillate Manifold Components, GS-90 (option)........................................101 7-5 Welder Manifold Components (option)..................................................103 7-6 Valve Adjustments - Function Manifold................................................104 How to Adjust the System Relief Valve................................................104 How to Adjust the Steer Relief Valve.................................................105 7-7 Valve Adjustments - Traction Manifold................................................106 How to Adjust the Charge Pressure Relief Valve.......................................106 7-8 Generator Manifold Components........................................................107 7-9 Valve Adjustments - Generator Manifold...............................................108 How to Adjust the Generator Voltage..................................................108 7-10 Generator Relief Valve Manifold Components..........................................109 7-11 Valve Coils.........................................................................110 Fuel and Hydraulic Tanks.....................................................................112 8-1 Fuel Tank............................................................................112 8-2 Hydraulic Tank.......................................................................113 Steer Axle Components........................................................................115 9-1 Yoke Assembly........................................................................115 How to Remove the Yoke and Drive Motor...............................................115 How to Remove a Drive Motor..........................................................116 9-2 Steer Cylinder.......................................................................117 9-3 Oscillating Axle Option - GS-90 Models...............................................117 Non-steer Axle Components....................................................................119 10-1 Drive Motor and Brake...............................................................119 How to Remove a Drive Motor and Brake................................................119 10-2 Drive Hub...........................................................................120 How to Remove a Drive Hub............................................................120 10-3 Oscillating Axle....................................................................120 Outrigger Components.........................................................................121 11-1 Outrigger Cylinder..................................................................121 How to Remove an Outrigger Cylinder (if equippe
d)....................................121 Platform Overload Components.................................................................122 12-1 Platform Overload System (if equipped)..............................................122 How to Calibrate the Platform Overload System (if equipped)..........................122 12-2 Platform Overload Recovery Message..................................................124 12-3 Down Limit Height...................................................................125 How to Calibrate the Down Limit Height...............................................125 Fault Codes......................................................................................127 Introduction.................................................................................128 Control System Fault Codes...................................................................129 Platform Overload Fault Codes................................................................134 Fault Code Display - Deutz Models............................................................139 How to Retrieve Active Engine Fault Codes Deutz D 2.9 L4 Models..........................139 How to Retrieve Active Engine Fault Codes - Deutz TD 2.2 L3, D 2.9 L4 Stage IV Models....140 Fault Code Display - Flashing and Solid LED's - Deutz D 2.9 L4 Models....................141 Soft Key Functions and Icons - Deutz D 2.9 L4 Models.....................................142 Soft Key Functions and Icons - Deutz TD 2.2 L3 Models....................................143 Main Menu Structure - Deutz D 2.9 L4 Tier IV Models......................................144 Main Menu Structure - Deutz TD 2.2 L3 Models.............................................145 Deutz D 2.9 L4 Tier IV Engine Fault Codes....................................................146 Deutz TD 2.2 L3, D/TD 2.9 L4 Stage IV Engine Fault Codes.....................................157 Deutz D436 L3i Engine Fault Codes............................................................167 Ford MSG-425 Engine Fault Codes..............................................................169 How to Retrieve Ford Engine Fault Codes..................................................169 How to Clear Engine Fault Codes from the ECM.............................................169 Ford MSG-425 Engine Fault Codes..........................................................170 Fault Code Display - Weichai Models..........................................................175 How to Retrieve Active Engine Fault Codes - Weichai WP3.2 Models.........................175 Main Menu Structure - Weichai WP3.2 Models...............................................176 Weichai WP3.2 Engine Fault Codes.............................................................177 Schematics.......................................................................................181 Introduction.................................................................................181 Electrical Symbols Legend....................................................................182 Hydraulic Symbols Legend.....................................................................183 Electrical Component and Wire Color Legends..................................................184 Ford Engine Relay Layout.....................................................................186 Electronic Control Module Layout.............................................................187 Electronic Control Module Pin-Out Legend.....................................................188 Ground Controls Wiring Panel Layout..........................................................190 Wiring Diagram - Platform Control Box........................................................191 Limit Switch Legend..........................................................................192 Wiring Diagram - 12 kW Hydraulic Generator (option)..........................................193 Electrical Schematics - Engine Harness.......................................................195 Ford MSG-425 EFI Engine Wire Harness.....................................................196 Deutx D 2.9 L4 Tier IV Engine Wire Harness...............................................197 Deutz D 2.9 L4 Stage IV Engine Wire Harness..............................................200 Deutz TD 2.2 L3 Engine Wire Harness (to GS90D-3429)......................................204 Deutz TD 2.2 L3 Engine Wire Harness (from GS90D-3430)....................................208 Weichai WP3.2 Engine Wire Harness........................................................211 Electrical Schematics – ANSI and CSA Models..................................................213 Electrical Schematic, Ford Engine Models (ANSI/CSA)......................................214 Electrical Schematic, Deutz Engine Models (ANSI/CSA).....................................218 Electrical Schematic, SCON (ANSI/CSA)....................................................221 Electrical Schematics – AS and CE Models.....................................................223 Electrical Schematic, Ford Engine Models (AS/CE).........................................224 Electrical Schematic, Deutz and Weichai Engine Models (AS/CE)............................228 Electrical Schematic, SCON (AS/CE).......................................................231 Hydraulic Schematics.........................................................................233 Hydraulic Schematic......................................................................234 Back Cover.......................................................................................237
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