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Genie GS-3384 Service Manual 82259 – PDF DOWNLOAD
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Description
Genie GS-3384 Service Manual 82259 – PDF DOWNLOAD
Language : English
Pages : 304
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie GS-3384 Service Manual 82259 – PDF DOWNLOAD
Important Information.................................................................................................... 2 Table of Contents........................................................................................................ 7 Section 1 • Safety Rules................................................................................................. 5 Section 2 • Specifications - Rev D....................................................................................... 15 Machine Specifications............................................................................................... 15 Performance Specifications........................................................................................... 16 Hydraulic Specifications............................................................................................. 16 Manifold Component Specifications.................................................................................... 18 Valve Coil Resistance Specifications................................................................................. 18 GM 1.6L Engine....................................................................................................... 19 Ford LRG-425 EFI Engine.............................................................................................. 20 Deutz F3L 1011F Engine............................................................................................... 21 Deutz F3L 2011 Engine................................................................................................ 22 Deutz D2011L03i Engine............................................................................................... 22 Hydraulic Hose and Fitting Torque Specifications..................................................................... 23 SAE and Metric Fasteners Torque Charts............................................................................... 24 Section 3 • Scheduled Maintenance Procedures............................................................................. 25 Introduction......................................................................................................... 25 Pre-delivery Preparation............................................................................................. 27 Maintenance Inspection Report........................................................................................ 29 Checklist A Prodcedures - Rev E...................................................................................... 31 A-1 Inspect the Manuals and Decals............................................................................... 31 A-2 Perform Pre-operation Inspection............................................................................ 32 A-3 Perform Function Tests...................................................................................... 32 A-4 Perform Engine Maintenance - Ford Models.................................................................... 33 A-5 Perform Engine Maintenance - Deutz Models................................................................... 33 A-6 Check the Engine Coolant Level - GM Models.................................................................. 34 A-7 Inspect the Engine Air Filter - GM Models................................................................... 35 A-8 Check the Battery - GM Models............................................................................... 36 A-9 Inspect the Radiator - GM Models............................................................................ 37 A-10 Check the Engine Fasteners - GM Models..................................................................... 38 A-11 Perform 30 Day Service..................................................................................... 38 A-12 Perform Engine Maintenance - Deutz Models.................................................................. 39 A-13 Perform Engine Maintenance - Ford Models................................................................... 39 A-14 Check the Alternator Belt - GM Models...................................................................... 40 A-15 Check the Hydraulic Return Filter Condition Indicator (if equipped)........................................ 41 A-16 Perform Engine Maintenance - Deutz 1011F Models............................................................ 41 A-17 Drain the Fuel Filter/Water Separator - Deutz Models....................................................... 42 A-18 Perform Engine Maintenance - Ford Models................................................................... 43 A-19 Replace the Engine Oil and Filter - GM Models.............................................................. 43 Checklist B Prodcedures - Rev F...................................................................................... 45 B-1 Inspect the Battery......................................................................................... 45 B-2 Inspect the Electrical Wiring............................................................................... 46 B-3 Perform Engine Maintenance - Deutz 1011F Models............................................................. 47 B-4 Check the Exhaust System.................................................................................... 47 B-5 Inspect the Engine Air Filter - Ford and Deutz Models....................................................... 48 B-6 Check and Adjust the Engine RPM............................................................................. 49 B-7 Confirm the Proper Brake Configuration...................................................................... 51 B-8 Inspect the Tires and Wheels (including lug nut torque)..................................................... 51 B-9 Check the Oil Level in the Drive Hubs....................................................................... 52 B-10 Test the Key Switch........................................................................................ 52 B-11 Test the Emergency Stop.................................................................................... 53 B-12 Test the Automotive-style Horn............................................................................. 53 B-13 Test the Fuel Select Operation - Ford and GM Models........................................................ 54 B-14 Test the Drive Brakes...................................................................................... 55 B-15 Test the Drive Speed - Stowed Position..................................................................... 55 B-16 Test the Drive Speed - Raised Position..................................................................... 56 B-17 Perform Hydraulic Oil Analysis.............................................................................. 57 B-18 Inspect the Fuel and Hydraulic Tank Cap Venting Systems.................................................... 58 B-19 Replace the Engine Air Filter Element - Ford and GM Models................................................. 59 B-20 Perform Engine Maintenance - Ford Models................................................................... 60 B-21 Replace the Fuel Filter - GM Models........................................................................ 60 B-22 Check the Specific Gravity of the Engine Coolant - GM Models............................................... 61 Checklist C Prodcedures - Rev D...................................................................................... 63 C-1 Test the Platform Overload System (if equipped)............................................................. 63 C-2 Replace the Engine Air Filter Element - Deutz Models........................................................ 64 C-3 Perform Engine Maintenance - Deutz Models................................................................... 65 C-4 Replace the Hydraulic Tank Breather Cap - Models with Optional Hydraulic Oil................................ 65 C-5 Perform Engine Maintenance - Ford Models.................................................................... 65 C-6 Clean the PCV Hoses and Fittings - GM Models................................................................ 66 C-7 Change or Recondition the Engine Coolant - GM Models........................................................ 66 C-8 Replace the LPG Filter - GM Models.......................................................................... 67 C-9 Replace the Spark Plugs and Spark Plug Wires - GM Models.................................................... 68 Checklist D Prodcedures - Rev E...................................................................................... 69 D-1 Check the Scissor Arm Wear Pads............................................................................. 69 D-2 Check the Free-wheel Configuration.......................................................................... 70 D-3 Replace the Drive Hub Oil................................................................................... 71 D-4 Replace the Diesel Fuel Filter/Water Separator - Deutz Models............................................... 71 D-5 Replace the Hydraulic Filters............................................................................... 72 D-6 Perform Engine Maintenance - Deutz Models................................................................... 74 Checklist E Procedures - Rev B....................................................................................... 75 E-1 Test or Replace the Hydraulic Oil........................................................................... 75 E-2 Change the Fuel Hoses - GM Models........................................................................... 77 E-3 Perform Engine Maintenance - Deutz 1011F Models............................................................. 79 E-4 Perform Engine Maintenance - Ford Models.................................................................... 80 E-5 Perform Engine Maintenance - Deutz Models................................................................... 80 E-6 Perform Engine Maintenance - Deutz 2011 Models.............................................................. 80 Section 4 • Repair Procedures............................................................................................ 81 Introduction......................................................................................................... 81 Platform Controls - Rev C............................................................................................ 82 1-1 Circuit Boards.............................................................................................. 83 1-2 Joystick Controller......................................................................................... 83 1-3 Controller Adjustments (before serial number GS8403-40213).................................................. 85 1-4 Software Configuration (before serial number GS8403-40213).................................................. 91 Platform Components - Rev B.......................................................................................... 95 2-1 Platform.................................................................................................... 95 2-2 Platform Extension Deck..................................................................................... 97 Scissor Components - Rev B........................................................................................... 98 3-1 Scissor Assembly, GS-3384................................................................................... 98 3-2 Wear Pads...................................................................................................104 3-3 Lift Cylinder...............................................................................................106 Engines - Rev C......................................................................................................108 4-1 RPM Adjustment..............................................................................................108 4-2 Engine Fault Codes - Ford Models............................................................................108 4-3 Flex Plate..................................................................................................108 4-4 Oil Temperature and Oil Pressure Switches - Deutz Models....................................................113 4-5 Coolant Temperature and Oil Pressure Switches - Ford Models.................................................114 4-6 Coolant Temperature and Oil Pressure Switches - GM Models...................................................115 Ground Controls - Rev C..............................................................................................116 5-1 Auxiliary Platform Lowering.................................................................................116 5-2 Controller Adjustments (after serial number GS8403-40212)...................................................116 5-3 Software Configuration (after serial number GS8403-40212)...................................................127 5-4 Level Sensor - Models without Outriggers (before serial number 40077).......................................131 5-5 Level Sensor - Models without Outriggers (after serial number 40076)........................................134 5-6 Level Sensor - Models with Outriggers.......................................................................136 5-7 Engine Fault Codes - Ford Models............................................................................141 Hydraulic Pumps - Rev C..............................................................................................142 6-1 Lift/Steer Pump.............................................................................................142 6-2 Drive Pump..................................................................................................144 Manifolds - Rev E....................................................................................................146 7-1 Function Manifold Components - Models with Outriggers.......................................................146 7-2 Function Manifold Components - Models without Outriggers....................................................148 7-3 Drive Manifold Components (before serial number GS8404-40297)...............................................150 7-4 Drive Manifold Components (after serial number GS8404-40296)................................................152 7-5 Valve Adjustments - Function Manifold.......................................................................154 7-6 Valve Adjustments - Drive Manifold..........................................................................156 7-7 Generator Manifold Components...............................................................................158 7-8 Valve Adjustments - Generator Manifold......................................................................159 7-9 Valve Coils.................................................................................................160 Fuel and Hydraulic Tanks - Rev A.....................................................................................162 8-1 Fuel Tank...................................................................................................162 8-2 Hydraulic Tank..............................................................................................163 Steer Axle Components - Rev B........................................................................................165 9-1 Yoke and Drive Motor........................................................................................165 9-2 Steer Cylinder..............................................................................................167 9-3 Tie Rod.....................................................................................................167 Non-steer Axle Components - Rev A....................................................................................168 10-1 Drive Motor and Brake......................................................................................168 10-2 Drive Hub..................................................................................................169 Outrigger Components - Rev B.........................................................................................170 11-1 Outrigger Cylinder.........................................................................................170 Platform Overload Components - Rev A.................................................................................171 12-1 Platform Overload System....................................................................................171 Section 5 • Fault Codes..................................................................................................179 Introduction.........................................................................................................179 Fault Code Chart (before serial number GS8403-40213) - Rev B.........................................................181 Fault Code Chart (after serial number GS8403-40212) - Rev A..........................................................183 Ford Engine ECM Fault Code Chart (before serial number GS8404-40302) - Rev A.........................................186 Ford Engine ECM Fault Code Chart (after serial number GS8404-40301) - Rev A..........................................188 Section 6 • Schematics...................................................................................................193 Introduction.........................................................................................................193 Electrical...........................................................................................................194 Electronic Control Module Layout (before serial number GS8403-40213) - Rev A.....................................194 Electronic Control Module Pin-Out Legend (before serial number GS8403-40213) - Rev A.............................194 Electronic Control Module Layout (after serial number GS8403-40212) - Rev A......................................196 Electronic Control Module Pin-Out Legend (after serial number GS8403-40212) - Rev A..............................197 Ford Engine Relay Layout - Rev A.................................................................................198 Wiring Diagram - Platform Control Box (before serial number GS8403-40213) - Rev A................................199 Wiring Diagram - Platform Control Box (after serial number GS8403-40212) - Rev A.................................200 Electrical Schematics Abbreviation and Wire Color Legends - Rev A................................................201 Electrical Symbols Legend - Rev A................................................................................202 Limit Switch Legend - Rev A......................................................................................203 Wiring Harness - GM 1.6 L Rev A..................................................................................205 Wiring Harness - Ford LRG-425 EFI (before serial number GS8404-40302) - Rev A....................................206 Wiring Harness - Ford LRG-425 EFI (after serial number GS8404-40301) - Rev A.....................................208 Electrical Schematic - GM Models (before serial number 40044) - Rev C............................................210 Electrical Schematic - GM Models (from serial number 40044 to 40067) - Rev C.....................................214 Electrical Schematic - GM Models (from serial number 40068 to GS8403-40131) - Rev C..............................218 Electrical Schematic - GM Models (from serial number GS8403-40132 to GS8403-40212) - Rev B.......................222 Electrical Schematic - GM Models (after serial number GS8403-40212) - Rev B......................................226 Electrical Schematic - ANSI Models with Ford Power (before serial number GS8404-40302) - Rev D...................230 Electrical Schematic - ANSI Models with Ford Power (from serial number GS8404-40302 to GS8405-40504) - Rev D.....234 Electrical Schematic - ANSI Models with Ford Power (from serial number GS8405-40505 to GS8405-40539) - Rev C.....238 Electrical Schematic - ANSI Models with Ford Power (from serial number GS8405-40540 to GS8405-40832) - Rev B.....242 Electrical Schematic - CE Models with Ford Power (before serial number GS8404-40302) - Rev D.....................246 Electrical Schematic - CE Models with Ford Power (from serial number GS8404-40302 to GS8405-40504) - Rev D.......250 Electrical Schematic - CE Models with Ford Power (from serial number GS8405-40505 to GS8405-40539) - Rev D.......254 Electrical Schematic - CE Models with Ford Power (from serial number GS8405-40540 to GS8405-40617) - Rev C.......258 Electrical Schematic - CE Models with Ford Power (from serial number GS8405-40618 to GS8405-40832) - Rev C.......262 Electrical Schematic - Deutz Models (before serial number 40044) - Rev C.........................................266 Electrical Schematic - Deutz Models (from serial number 40044 to 40067) - Rev C..................................270 Electrical Schematic - Deutz Models (from serial number 40068 to GS8403-40131) - Rev C...........................274 Electrical Schematic - Deutz Models (from serial number GS8403-40132 to GS8403-40212) - Rev B....................278 Electrical Schematic - ANSI Models with Deutz Power (from serial number GS8403-40213 to GS8405-40504) - Rev D....282 Electrical Schematic - ANSI Models with Deutz Power (from serial number GS8405-40505 to GS8405-40832) - Rev C....286 Electrical Schematic - CE Models with Deutz Power (from serial number GS8403-40213 to GS8405-40504) - Rev D......290 Electrical Schematic - CE Models with Deutz Power (from serial number GS8403-40505 to GS8405-40832) - Rev C......294 Hydraulic............................................................................................................297 Hydraulic Schematics Component Call-out and Symbols Legend - Rev A...............................................297 Hydraulic Schematic (before serial number GS8404-40297) - Rev C..................................................298 Hydraulic Schematic (from serial number GS8404-40297 to GS8405-40832) - Rev D....................................300
S.S 05/24
